I recently purchased a used F150 SB, 4.2/5spd and 10k miles. The exhaust has a leak where the driver's side exhaust pipe makes a 90 degree turn to connect to the cross pipe that connects to the passenger side exhaust (under the cab). There is a ring type clamp where the driver's side pipe and cross pipe connect that is tack welded in place. Should this ring have been welded all the way around or do I have a defective exhaust pipe. The leak is audible, as well as having condensate dripping out when the engine is cold. There is also a lot of black soot around the leak. Any info would be appreciated.

 

my 99 4.2 has the same audible sound and dripping from the exhaust,I took it back to the dealer and they said that it was normal and that there was no leak. It sounds like crap. Surely these exhaust systems shouldnt make this much noise.

 

I was lucky enough to get an appointment this past Saturday at my local Ford dealer to have the exhaust system inspected. The mechanic that worked on my truck said he tightened the clamps. The noise has gone away. I haven't checked for any condensation dripping yet.