PEP 11 - Exhaust

PEP Program No. 11 March, 2002

Exhaust

TM

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The Function of the Exhaust System

The primary function of the exhaust system is to carry engine gasses from the engine compartment to a safe exit point. Exhaust systems are designed to provide the best balance between noise reduction, pollution control, fuel efficiency and driver comfort. Leaking, worn, damaged and poorly maintained systems result in poor vehicle performance, excessive noise and possible personal injury from inhalation of gasses and pollutants.

Exhaust Components

The heavy-duty exhaust system consists of a few basic components that are readily replaced. Pipe, elbows, mufflers, clamps and various accessories like rain caps, adapters, spouts, heat shields and hangers are frequent replacement items required to maintain a safe and efficient system. Each system has unique features that require use of appropriate components. Precise application data and precision-engineered components assure proper system function.

Dayton Parts distributes Walker exhaust components. Walker is the industry leader in quality engineered emission control products. Walker produces thousands of OEM design/style components with unmatched fit and quality for all types of vehicles.

Mufflers — Mega-Flow , Severe Service, Noise-Breaker Elbows — Aluminized, Stainless, Chrome, Steel Stacks — Aluminized and Chrome Flex Pipe — Standard and Heavy-Duty — Galvanized, Aluminized, Stainless Straight Pipe — Standard and Heavy-Duty — Aluminized, Steel Hangers of all shapes and sizes Connectors and Adapters Spark Arrestors and Shields Rain Caps Clamps TM

E X H AU S T S Y S T E M S

Walker Quality — CAD/CAM design Walker Fit — OEM design/style Walker Availability — Broadest coverage of ANY heavy-duty exhaust company

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Exhaust

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Inspecting Exhaust Systems Technical Information

The most common sign of exhaust system failure is increasing noise from the system. This is an indication that the muffler may be starting to wear out, but it may not be the only cause of excessive exhaust noise. The vehicle may not have the proper muffler installed, low restriction mufflers may be cheap but they can generate excessive noise. Always start an inspection at the engine and work your way to the muffler. Carefully look at all of the piping, connections, seams and elbows for any indication of a leak. The first tell tale sign of an exhaust leak is black streaks or soot on the outside of the pipe. Caution: Road contaminants and oil can mask defective areas. Excessively dirty exhaust system may require the engine to be started to listen carefully at joints and welds for leaks. If a suspect area is found, a screwdriver or other pointed object should be used to poke around the area. Usually the metal will be soft and thin at the defective area. By probing, you may penetrate the pipe easily. Areas more prone to failures, outside radius of an elbow or bend in a pipe, the metal is stretched in these areas and is thinner. Welds can and do crack, so be certain to check these as well. Muffler seams are prone to corrosion, which can be a source of leaks as well. Corrosion can take place inside the exhaust system it is caused by a mixture of exhaust sulfur and moisture. Inspect for missing or broken clamps. Vibration is major cause of exhaust system failure. It can virtually break the tubing or connection. Inspect the system the proper support hangers and brackets.

Walker Exhaust Components

Dayton Parts, Inc.

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Mufflers — All Mufflers Are Not Created Equally The muffler is critical to the performance of the exhaust system. Mufflers should not be replaced based only on size. When choosing a muffler, fuel efficiency, life expectancy, sound abatement, cost and appearance are all important issues. Specifying the muffler for a class 7 or 8 truck is based on engine make and model not the truck. The rest of the system is assembled like plumbing, using elbows, flex, connectors and accessories. Look for these features when selecting heavy-duty replacement mufflers to assure the best combination of quality and value.

Low backpressure fuel economy Heavy material gage durability

Domed end caps eliminate water build up, smooth exhaust flow Bridge construction added strength against vibration damage Lock seam construction superior corrosion resistance Decibel (db) rating for compliance with rising noise reduction standards

Pipes, Elbows & Stacks

Mega-Flow™

Mandrel bent elbows smooth exhaust flow and reduce back pressure for greater fuel economy Available in chrome, stainless, aluminized and cold rolled steel 14 gage aluminized elbows and pipe resist corrosion and scaling Straight lengths of pipe available in 10 foot lengths Flex pipe available in 6, 10 and 25 foot lengths made from standard and heavy galvanized steel, aluminized or 304 stainless Chrome is applied by Lincoln Plating, exclusive plater for Harley Davidson using a 29 step process, ensuring durable good looks.

Specifically designed for Class 7 and 8 vehicles, Mega-Flow combines Walker quality and engineering with cutting-edge technology to deliver unparalleled p e r f o rma n c e ; a s mu c h a s 30% backpressure reduction without sacrificing acoustics. That means efficiency and driver comfort! Mega-Flow is built to last. A unique, specialized treatment ensures improved corrosion resistance. And Mega-Flow is backed by the best warranty in the business. Mega-Flow combines an open style design with OCF roving to produce a product that improves fuel efficiency without impact to acoustics; two key needs of the fleet. Other mufflers currently available address one, at the expense of the other.

Clamps

Exclusive Mega-Seal band clamps keep it all together with the thickest steel bands on the market reinforced with grade eight bolts. Line includes a variety of flat and preformed band clamps. Stainless and aluminized U-bolt clamps in heavy-duty and standard grades Chrome and zinc plated available in most popular sizes

Mega-Clamp™ Available in a wide range of styles and sizes, including 304 Stainless Steel and Aluminized. Mega-Clamp has the answers for your heavy-duty requirements. Walker quality ensures superior sealing capability for reduced leakage rates. And the easy, one-wrench, one-hand installation saves you time and effort when it counts. Mega-Clamp offers extra strength and durability with the thickest steel bands on themarket, reinforced by grade 8 bolts. For longer life, greater corrosion resistance and sharp appearance, get Mega-Clamp. We’re keeping it all together — with quality!

V band clamps Air line clamps

Accessories

Hangers Air intake

Connectors and adapters Spark arrestors and shields Rain caps

Dayton Parts, Inc.

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Features and benefits Your Dayton Parts Distributor can supply your complete exhaust replacement needs with the best combination of quality and value available. Quality - Fit - Availability Mega-Flow™ - Mega-Clamp™ - Noise Breaker - Severe Service Chrome - Zinc Galvanized - Aluminized - Stainless 18 gage aluminized construction Domed heads Lock seam construction Bridge constructed inlet and outlets Mega-Flow Patented internal design 4 year, half-million mile warranty 60 day “safe & sound” guarantee Mufflers

Pipes, Elbows & Stacks

Mandrel bent, 14 gage aluminized elbows, 15, 30, 45, 60, 67, 70 & 90 degree bends Aluminized, Stainless and cold rolled steel tubing Spout, square and slant cut stacks 29 step double-nickel chrome plating process Heavy and standard wall galvanized, aluminized and stainless flex pipe

Clamps

Mega-Seal band clamps Variety of flat and preformed, stainless and aluminized band clamps Standard and heavy-duty u-bolt clamps available, chrome and zinc plated

Accessories

Hangers of all shapes and sizes Air intake components Connectors, adapters and reducing bushings Rain caps — standard and silent, chrome and standard finishes available Spark arrestors Shields — chrome, aluminized and zinc plated

Catalogs and Support Materials

Heavy Duty, Agricultural & Industrial Exhaust Systems Catalog School Bus Catalog Severe Service Catalog Point of purchase sales kit, includes banner and counter mat Assorted product specific brochures and flyers Exhaust Component Wall charts

Dayton Parts, Inc.

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