My 02 MCS W/ 118,000 just picked up a new exhaust note. I put the car up on a rack to look for the source (leak). Using a stethoscope I found it to be leaking inside the bell shaped coupler ahead of the cat. I can't see where the coupler is welded to the pipe that goes to the cat, or what holds it together. But the exhaust is definitely leaking from up inside that bell coupler. All the braided flex joints are in good shape and not leaking.

Can someone describe what is used to join those together and has anyone ever had a leak there and repaired it?

Thank you for your feedback.

 

Is this the area ?



May be tough getting to this location w/o removing the exhaust manifold/cat to do it.

Any CEL's from having the leak ?

 

For us it is all one piece too (About $1,350.00 from dealer), but would be covered under federal guidelines for warranty replacement 8yrs/80,000 miles.

You and I are both beyond that mileage wise....unfortunatley.

 

Correct, the red arrows point to the joint I was referring to. Any explanation of what that odd joint does? Is it a flex coupling or something.

I'm not too concerned with the small amount of exhaust leaking, however if it is a cracked weld up inside which would most likely get worse with time, I don't want the exhaust system falling apart while I'm traveling.

Perhaps its time for a header and weld some flanges on the Catholic converter, and reinstall.

Anyone else have a failure at the coupler?

 

That's your pre-cat. It isnt important so you could just have an exhaust shop hack it off and weld a pipe there.