Exhaust Cracked
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Joined: Nov 2004
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Exhaust Cracked
Driving home in my stock 2001 X, I noticed the exhaust had just gotten appreciably louder. I checked and saw that the 3" SS pipe between the cat and the muffler and sheared in two. (looks like the pipe attached to the muffler) Saw no rust spots. Only thing I could think of is that there was too much torque twisting the muffler when it was installed.
Since it is jaggedly broken around the complete circumference of the pipe, it this weldable? Or am I looking at a new muffler? Anyone else have this problem?
I assume it is too late for warranty at 76,500 miles!
Thanks much..
Since it is jaggedly broken around the complete circumference of the pipe, it this weldable? Or am I looking at a new muffler? Anyone else have this problem?
I assume it is too late for warranty at 76,500 miles!
Thanks much..
FTE NC Chapter
Joined: Oct 2007
Posts: 2,971
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From: Coastal NC
My 04 did the same thing two weeks ago. Same location. Right at the bend between the cat and muffler. I figured mine was due to being off road and being stressed often. But apparently, it's a known issue. 
I wonder what makes the pipe crack in that location. Mine split in half and was very ragged. Not a clean split.
The split was far enough away from the muffler that I could get a patch/pipe welded in place. No issues with the fix. Cost me 25$ and about twenty minutes of time.
I wonder what makes the pipe crack in that location. Mine split in half and was very ragged. Not a clean split. The split was far enough away from the muffler that I could get a patch/pipe welded in place. No issues with the fix. Cost me 25$ and about twenty minutes of time.
Senior User
Joined: Sep 2003
Posts: 130
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From: British Columbia, Canada
Mine cracked at least 3 times under warranty. Ford replaced the entire cat to tailpipe all 3 times as welding it was not covered by warranty. And we all want to save the earth right!?
The 4th time it cracked, I went to a muffler shop. They welded it and put a hanger on it right between the cat and muffler. That was at about 85,000 Kms.
It finally cracked again about 1 month ago (190,000 kms). The hanger had broken some time ago. My daughter is now a welder and did a great job of welding it back together and re-enforcing it. I fixed the hanger.
That S pipe now looks like Frankenstien's donor parts scars. But until the system rots out and I put an entire after market unit on, it will do just fine thanx.
The 4th time it cracked, I went to a muffler shop. They welded it and put a hanger on it right between the cat and muffler. That was at about 85,000 Kms.
It finally cracked again about 1 month ago (190,000 kms). The hanger had broken some time ago. My daughter is now a welder and did a great job of welding it back together and re-enforcing it. I fixed the hanger.
That S pipe now looks like Frankenstien's donor parts scars. But until the system rots out and I put an entire after market unit on, it will do just fine thanx.
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