1st time Mini owner - I just bought a 2005 Mini Cooper S and after two days, the exhaust got really loud and the service engine light came on. It's throwing a R0137 error for the downstream O2 sensor. I got a new sensor and jacked up the car and crawled under and discovered the exhaust isn't connected to the down pipe. I'm not sure if a cat removal project was aborted or what. There were signs of a tack weld that has since busted loose. So, do I attempt to manufacture something that holds this together, or buy a whole new exhaust assembly?


Disconnected just after the 1st O2 sensor. Weld marks at 10:00 and 4:00.

 

Maybe you could find a muffler shop to do a proper weld repair.

Or might be just the incentive to begin the mods!

 

That separation is a fairly common problem. There are a number of guys on this forum that have simply had it rewelded.