I'm driving down the Interstate, this minivan drives by & I think "man that thing sounds like crap". Then I realize OH CRAP! it's me. Being that it was late afternoon on a Saturday I had little choice but to drop by Express Oil change to learn that a weld in my exhaust system has broken. Don't know much about this stuff. They guy said something like 3 or 4 pipes come off the engine & meld into one pipe & that one pipe had an irreparable break in the weld. My MINI sounds like a ghastly mating of a race car with a redneck glass packed truck. That former music-to-my ears Supercharger whine & patpatpat out of my tailpipe now sounds like a nightmare on crack!

I am just trying to find out before Monday how bad & costly this might be. Is this a part I should seek out on NAM from someone who has done an aftermarket exhaust replacement? Is this something I should start a junkyard search for? Is this one of those parts that MINI only sells as a megapriced whole part? How much am I looking at? Please ease my mind... I have a 2005 MCSC.

Thanks in advance for any help you might offer in allowing me to maintain my sanity without lots of beer over the next 2 days

 

Hi T! I'd start by calling Way Motor Works - he's (relatively) nearby, and likely has a spare or two. Definitely $$$ from MINI, but there should be a reasonable stock in the wrecker world.

 

EGADS I am so broke! Any estimates on what I might be in for?

 

The Megan w/o cat is $170, so a used OEM shouldn't be any more, and should be less. All depends on supply and demand though.

 

Thanks old school loves for the help.. luv u guys OMG that relieves me. If it comes down to it should I go aftermarket in some way? Any clue what part or description of part I may need for my hunt Monday morning. I'll call Way but will he know what I am talking about?

 

He'll know, but it's call the exhaust manifold, or 'header'. OEM (original) versions come with the catalytic converter attached. Some aftermarket pieces require welding a cat onto them. Way will send you on the right path. These days it seems like he's NAM's Yoda.

 

Danke Schön

 

Last I knew, in compliance with federal regulations, during resale and/or trade-in the car will have to have a cat. And if the O2 sensors are not wired in, your going to have CEL's all day long as they assist with fuel air managment.

When the DME (ECU) senses a lean condition due to some unforseen circumstances or part malfunction, the signal from the pre-cat sensor tells the DME to dump more fuel to cool things off. Especially important in air force fed machines like ours....cylinder head temps climb and decline rapidly when in boost.

That said, last I knew, there been some MINI drivers who have gone catless w/O2 bungs that still get CEL's - for whatever reason.....Maybe it's the design.

So IMO, if you can't afford the MINI premium price of about $1,300.00 then search for a good used one.

 

Any welder worth his salt should be able to fill and weld close that hole which I assume is a crack in the existing weld. Removing and replacing that exhaust maniifold will not be fun due to rusted & seized bolts/nuts/studs that you will find and have to replace plus all the gaskets along the way. If the cat is welded on it, then so much the worst.
A competant muffler shop should be able to do it for a reasonable amount.
I do not have direct experience with this on the mini but I have done it on my volvo and it was not fun. My 2 cents.

 

an irreparable break in the weld

sounds like a person that either can't weld, or doesn't want the job. If it is steel it can be welded.... now this might be just a temporary repair but irreparable??? I'd like to see pictures.


If a shop told me this I'd just smile, say thanks, and never get within 50 feet again. Find a better muffler shop....

Even if you have to crop out a chunk and weld in a joiner, this ain't major fabrication work..... I'm a hack welder but this wouldn't scare me; sounds very doable for me and Mr MIG.

problem may just be you asked an oil change place how to fix a muffler! Try Midas!

 

Oh I will def be getting a more qualified opinion tomorrow. I only went to Express Oil because it happened at 3:30 on a Saturday afternoon so I didn't have much choice. Plus they were close & I wanted to be sure the MINI was safe to drive home

 

you can have your main cat fabricated to fit an aftermarket header and your Mini will throw no CEL's. As far as aftermarket headers go you get what you pay for. I have a Madness header for sale and can haggle a little on price(trying to get money up for the Dragon in April).

https://www.northamericanmotoring.co...t/16143/cat/22

 

Thank you Newts Muffler & Welding Shop.... I hope... The guy there told me he thinks the break is at the catalytic converter & by federal mandate it is under warranty for 8 years/80,000 miles. He said he has seen the breaks there before, they are due to a poor weld at the factory, & they are warrantied. Waiting to hear back from the MINI dealership but please oh please let the break be there

 

It was freefreefree

Covered under the catalytic 8 yr/80K mile warranty. Got a new exhaust manifold! Thanks & whew!