[Gino]

I think I found the source of my exhaust leak... whadda ya think? :rotf:

Any ideas what may have caused this? Does it look too "sooty" at all?

Looks like the support piece (flat piece of metal holding the two pieces together) went first then took out the rest of the weld holding the "muffler" on...

2002 LT w/102K.....

 

[Dick]

I think I found the source of my exhaust leak... whadda ya think? :rotf:

Any ideas what may have caused this? Does it look too "sooty" at all?

Looks like the support piece (flat piece of metal holding the two pieces together) went first then took out the rest of the weld holding the "muffler" on...

2002 LT w/102K.....

Hi, Gino - yep, it's normal!!! Actually, been several cases of that weld giving way. And for some reason, many of the ones I recall having that problem were the early model years ('99 thru '03). Three examples happened here in Boerne. One feller even tried the muffler wrap solution from Auto Supply store!! - didn't hold on the 100 mile trip to the Austin dealer! A good SS welder may fix that, butt he'll need to address the alignment situation. Might be better to find a used system - they've been on eBay now and then. If you go that route, make sure it's in the '99 - '04 model year range. Pipe thickness changed in the later years and the fitment is different. Good luck, Gino.

 

[saddleman]

The sooty look & color is normal for unleaded fuel.

 

[gunny]

TIG weld it back together.

 

[Scouter-50]

TIG weld it back together.

+1 on the TIG. If you were closer I'd say come on over to my home shop. I have a TIG machine and we could weld it back together in the space of two beers.
Robert

 

[dshealey]

Mine had cracked about half way around there, I TIG welded it better than stock. On mine it was evident the welding robot was not correctly aligned with the joint. The joint was on one side of the bead, not in the middle, as it should have been.