I've noticed a slight exhaust leak that started a couple weeks ago (barely noticeable then). Over the past few days it got noticeably louder and had a resonance in the cabin at certain RPMs. Well today it got VERY LOUD and the resonance about vibrated my teeth out.

I got the car up and noticed that the weld from the header/downpipe onto the cat has broken.
Is this something a local exhaust shop should be able to fix? Can they just replace the cat? Do I need an entire new header w/ cat??
Thanks.

See the photo

 

I think that the emissions stuff is warranted for 10 years. I would find out, you might get away with a small bill.

 

It wouldn't be that small considering the cost of towing. The nearest MINI dealer is over 80 miles away and I surely can't drive it like this.
Do you think it could be welded back on?

 

That is a warranty item. I would call them and see if they will come get it!

 

According to the Service Rep I just spoke to the warranty is 3 yr/36k miles even on the catalytic system.
Instant message service at Orlando MINI's website... very handy...
So it seems I either get it welded (if at all possible) or buy a replacement header.

 

Not that it helps you, but that's incorrect. At least in 2006 MINIs came with a 4 year/50,000 mile warranty.

It looks like the Federal Emissions Warranty covers "Specified major emission control components are covered for the first 8 years or 80,000 miles."
http://www.epa.gov/oms/consumer/warr95fs.txt

 

Thanks Claancy... but yeah... I'm screwed either way as far as warranty goes.

I took a closer look at it a few minutes ago. It completely separated all the way around. The top part is damaged a bit... would say rust but I can't really tell. I don't see how it could be welded back on properly.
I guess I'll be getting a cheap header like the Megan one and then having a cat welded in when I can.
Does the rear O2 put the system into "limp" mode if there is no cat?

 

Federal mandate for that warranty applies....the 3/36 does not apply to the cat or O2 sensors.

 

Do you think this is the same as the Megan header??
I have an Amazon gift card balance that would cover the cost... that's why I'm looking there.

 

Oh I just read more into that article Claancy...
Florida doesn't have inspection so... it wouldn't apply to me.

 

They will cover it if it is found to be defective, they have to. I had the cat on the Subaru pop a weld right at around 7 years and they covered it without question.

 

that cat is done. iv tried. you wont be able to weld it. the metal around it is way too thin and will just burn up making it even worse then it already is. i have megans and i really like it. do you have to do emissions where you live? if not you could just leave the cat out

 

You can find used OEM header/cat. on Ebay or even the marketplace on this forum for 2-3 hundred bucks.

Example : http://www.ebay.com/itm/MINI-Cooper-...318ea2&vxp=mtr

 

I realize your signature says 95k miles so your out of coverage but just to put it all to rest, federal emissions warranty on all cars is 8 years 80000 miles unless otherwise noted. NO car would have a lesser period of coverage although some have extended coverages as mandated by Epa for whatever reasons. It does not matter if your in whatever state you're in and whether or not they inspect vehicles. Ive been a tech in 3 different states now and the federal emissions law is mandated per the federal branch of the govt not state. Therefore it applies to everyone in the US.

That amazon header looks identical to the megan racing. I would try to stick with an OEM cat if you can find a used one, various aftermarket cats will still cause a check engine light.

My opinion of running sans cat is obnoxious. Not only will you always throw a check engine light for not having a cat but you would also not know if any other faults come up at any time as well unless you scan your ecu everyday. So you could potentially have another fault issue present itself and keep on driving never knowing until youre left broken down because you're check engine kight was already on the while time. Not to mention cars without cats smell, you and anyone around the car will be breathing in toxic hydrocarbons, and its wretched for the environment. But hey, its your car so its your call.

 

Can't remember which forum, but someone dyno'ed with and without a cat and found that the R53 lost power without the cat. The car requires some back pressure to run correctly.

 

I had mine welded 2 years ago. I think the guy MIG welded. It worked perfect. $65. Bucks

 

Correction to my previous post. It was TIG welded. Regardless worked like a champ