Steve Dummit
Member
Bought an 02 ST in March 03, with 13k and a Mercury certified warranty for 72/75K at a distant dealer in Goshen NY. In May 05, with 32K miles, the muffler broke where the pipe from the cat is welded to the body of the muffler. My local dealer in Mt Kisco NY replaced it under warranty. Now, 16 months later, at 53K miles, the new muffler broke again in the exact same place.
As I see it, the muffler should not be breaking twice in less than two years, especially at exactly the same place, unless there is something defective in the design of system. I do not do any offroading and I do not abuse the vehicle (other than New York potholes
). I have not modified anything except put a better airfilter on (as described by others on this site). I don't see how a less restrictive filter could lead to the weld breaking repeatedly between the pipe and muffler. The problem has to be in the way the pipe is suspended causing it to flex too much at that point. Or else Ford is selling shoddy equipment with weak welds.
The local dealer says it is no longer under warranty and wants $446.54 for a new stock muffler. I pointed out that it is supposed to be under a Ford certified warranty. He says take it back to the dealer I bought it from, which is 60 miles away. Not exactly on my way to work in the morning.
1. Is this typical Ford behavior? I was told when I bought the truck that the warranty was good at any dealer.
2. Are the stock Ford exhaust systems defective? Anybody else had this happen, once or repeatedly?
3. How do I convince Ford customer service (800-392-FORD) that this is their fault and it should be a warranty replacement?
4. If Ford won't do the honorable thing, are there any recommendations for fixing this at a muffler shop? Do I ask for them just to weld the broken part, or weld a new less restrictive muffler onto the old pipe?
I have really enjoyed the ST, despite the usual gripes about the godawful stock wranglers, the mileage, and the kangaroo rear suspension. But if this is the way Ford treats its customers, this will be my first and last Ford. I never had this sort of problem with Subaru or Honda, and I got my eye on that Ridgeline.
Thanks for any suggestions,
Steve
As I see it, the muffler should not be breaking twice in less than two years, especially at exactly the same place, unless there is something defective in the design of system. I do not do any offroading and I do not abuse the vehicle (other than New York potholes
). I have not modified anything except put a better airfilter on (as described by others on this site). I don't see how a less restrictive filter could lead to the weld breaking repeatedly between the pipe and muffler. The problem has to be in the way the pipe is suspended causing it to flex too much at that point. Or else Ford is selling shoddy equipment with weak welds. The local dealer says it is no longer under warranty and wants $446.54 for a new stock muffler. I pointed out that it is supposed to be under a Ford certified warranty. He says take it back to the dealer I bought it from, which is 60 miles away. Not exactly on my way to work in the morning.
1. Is this typical Ford behavior? I was told when I bought the truck that the warranty was good at any dealer.
2. Are the stock Ford exhaust systems defective? Anybody else had this happen, once or repeatedly?
3. How do I convince Ford customer service (800-392-FORD) that this is their fault and it should be a warranty replacement?
4. If Ford won't do the honorable thing, are there any recommendations for fixing this at a muffler shop? Do I ask for them just to weld the broken part, or weld a new less restrictive muffler onto the old pipe?
I have really enjoyed the ST, despite the usual gripes about the godawful stock wranglers, the mileage, and the kangaroo rear suspension. But if this is the way Ford treats its customers, this will be my first and last Ford. I never had this sort of problem with Subaru or Honda, and I got my eye on that Ridgeline.
Thanks for any suggestions,
Steve
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