My 1996 Subaru legacy wagon has been making some annoying rattling noises caused by a broken component within the exhaust system. The problem is that the flange coming from the cat to the resonator pipe has been completely rusted through. it looks like the resonator pipe has pulled it off over time, leaving the base of the flange on the output end of the Cat. I've been to two mechanic shops within the past week, and neither of them said they could fix the issue. I am now compelled to fix this problem myself, however, I need help as to how to go about fixing this problem. I probably could apply a large amount of silicone exhaust paste, get a new cat/resonator pipe, or try to cut the damaged section out and replace it somehow without a welder. Anyways I need your thoughts as to how to face this problem.
Go to a junk yard and replace the whole exhaust.
I had the same problem on my 2006 Forester. Fixed it with a split flange kit I've picked up from PepBoys: https://www.pepboys.com/nickson-laminated-split-flange/product/1234824
The connection is staying firm and isn't leaking for over a year now.
