I've been under the car 100 times but recently noticed for the first time that there is a lot of play — maybe 2 inches — in the exhaust system where the pipe meets the back end of the cat. Is this normal? At first I thought I lost a clamp but I checked the exhaust diagrams and there is no clamp there. It looks like the pipe just inserts into the cat. What made me check was that my exhaust sounded louder to me so I was looking for leaks.

 

Clamp is missing. https://www.ecstuning.com/b-genuine-...p/18302756352/

 

That's what I thought at first. In fact, I bought the clamp. But there's no lip on the pipe for the clamp. When I look at the parts diagrams, no clamp is shown.

 

The two pipes fit together like a ball and socket. The clamp fits over the two. Random photo from the net. Not my mess..

 

Yes clamp number 3 in the diagram is what your missing. Did someone recently do some work on your vehicle and inadvertently forget to re-install?

 

I beg to differ...the OP is showing a pix AFTER the flex pipe not right after the bend. there is no clamp in that area...make sure your welds are not broken.

I did an engine rebuilt and it snapped at that location. took the whole thing to a shop to get it welded.

Good luck.

 

Exactly. It's after. If there are supposed to be welds then they're definitely broken. No idea how that happened. Thanks.

 

Good call. I kept wondering why it looked a little off to me.

 

My bad I went off the wrong picture.

 

Do you drive your Mini in the winter months of the North East? I grew up in Connecticut and when I had vehicles like my honda accord the flex pipe at the joint broke on two of my vehicles. I suspect it was from the harsh road salt chemicals of the winter seasons.

 

I haven't driven it much the past few winters but I did when it was newer. And I can tell you that the chemicals they are using on the roads here in CT nowadays are toxic to cars so that could be it. Mechanics everywhere have horror stories.

Thanks, all, for your help. I should have been clearer at the start and posted this:

 

My R55 exhaust looked just like that after about 140,000 miles (New England - including winters). It was weird because it didn't sound bad, but I could slide the thing apart....it just kind of hung together until I had it welded. The weld lasted about 15,000 miles.