Exhaust Repair Question

cstimmons · March 30, 2004

Hello, :fire:

I had my 2000 Explorer worked on today by ford and I'm a little apprehensive about taking it back there. First off I'm not an "experienced" auto mechanic but I do know how to turn a wrench. Today they replaced the CAT and the sensor. I'm not sure if this is normal but instead of welding it or putting a new flange in they just stuck one pipe into the other and clamped it. I CAN HEAR A DEFINATE EXHAUST LEAK. Then I get underneith it and can feel it leaking. please look at these pictures and tell me if this is a "normal" repair job...Especially for warrenty work TYIA

EBInterceptor · March 30, 2004

I haven't dealt with Ford for exhaust issues, but I have had a place clamp the pipes before without problems. Welding it does give the best seal. I'd bring it back and make them weld it because they obviously didn't fix the problem. Welding takes a whole 5 minutes too.

Edit: The other pipe isn't suppose to have a flange like the other side. If you don't want to bring it back to the same dealer, then any exhaust shop would weld it for you. But if it was recent the dealer should do it for free.

Robb · March 30, 2004

I believe that it came stock clamped, so yes, that is what the dealer is going to do.

BUT, wow, those crimps look horrible. The pipes look two different sizes. If the leak is audible and can be felt, I would ride my a$$ right back up in there and complain my a$$ off!!

oh, btw.......maybe the wrong time, but Welcome Aboard!!!

edit: I take back the stock clamp comment. Stock was a flange, just like the existing pipe.

Isles4evr · March 30, 2004

Yeah that might be the worst clamp job I have ever seen. The problem with dealerships and exhaust is that most of them clamp. I worked at Volkswagen for a year and all we did was clamp. They actually didn't allow us to weld anything unless you were a certified welder, which noone was. I have clamped plenty of exhaust systems and welded just as many. When either is done properly there are minimal amounts of problems. I would defenetely take it back there and have them fix it though!

Chris

cstimmons · March 30, 2004

Thanks for the replies so far...I was going to post a hello in the newbie forum but was soo livid I wanted to get this done first. (if you know this allready ignore) it has 2 cats coming off the manifold and into the muffler...one of them was bad (loud rattle and caused sensor to go off). They replaced this under WARRENTY work...so wouldnt they be required to fix it the way it was orriginally (w/ two flanges) I wouldnt be so mad if they would have welded them and no leak BUT...we ordered the new cat on MAR. 3rd and just got it on monday....the dealership is 45 minutes away through california traffic and gass prices (not my fault, i'm stationed here, texas is were i want to be)

AGAIN thanks in advance if anyone knows the number/email addr. for the reginal service manager I'd appreciate it

cstimmons · April 1, 2004

UPDATE:

Took the vehicle back to AV Ford to have them re-do the work they've allready done. On the way back the Check engine light came back on. I got a rental car from them and they reshaped the pipe and did a pretty good job of welding it. They also replaced the CAT sensors AGAIN. Today I'm coming home from the gym and the check engine light comes back on.

I'm more than mad now.....Warrenty work on this car has cost my family 2 vacations so far and I'm going out of town on business next week. Not to mention this dealership is 45 min. away. My plan of attack now is to have an independant diagnostic done on the vehicle to ensure that it is in fact the same problem. Then I'm gonna contact the reginal service manager. If anyone knows a good point of contact I'd surely appreciate it.

Exhaust Repair Question

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Robb

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Isles4evr

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