Exhaust welds breaking
Thread Starter
Racer
Joined: Jun 2004
Posts: 323
Likes: 5
From: Austin Texas
Exhaust welds breaking
About two months ago the weld on the right rear exhaust pipe (where the three bolts go to the front one just in front of the axel) broke. I took it to a muffler shop and had it welded. Today I saw the exhaust tips vibrating again just like the first time and see that the weld is broke on the front pipe now. The left side is fine- what is causing the right side to break there? Most systems have flanged pipes and the part where the bolts go slides up to the flange but these ones are welded directly to the pipe. Seems like a poor design anyway but something has to be causing them to break.
Le Mans Master
Joined: Dec 2003
Posts: 5,561
Likes: 448
From: Atlanta metro Ga.
Originally Posted by wreakhavoc
About two months ago the weld on the right rear exhaust pipe (where the three bolts go to the front one just in front of the axel) broke. I took it to a muffler shop and had it welded. Today I saw the exhaust tips vibrating again just like the first time and see that the weld is broke on the front pipe now. The left side is fine- what is causing the right side to break there? Most systems have flanged pipes and the part where the bolts go slides up to the flange but these ones are welded directly to the pipe. Seems like a poor design anyway but something has to be causing them to break.
I'll bet money that a large majority of C5 owners have half-broken welds (my 14K mile 2000 had both sides hanging on with about 50% of the weld separated.) When I inspected the pipes, it's clear that the machine (or human) who welded these pieces did not penetrate the surrounding material enough for a good, strong long-lasting weld.
You can see the tail-tell signs; look for blackened areas right around the weld, where the exhaust gas is sneaking through.
Racer
Joined: Aug 2003
Posts: 290
Likes: 8
From: 60 miles from BGKY
Originally Posted by bob98
According to the Corvette shop I went to, they have seen a number of these on older C-5's. Had to replace my whole system ( we put on a 03 takeoff system on my 98)
Burning Brakes
Joined: Feb 2000
Posts: 1,247
Likes: 2
From: Parker, Colorado, USofA
Add another one to the list. The passenger side flange broke where it bolts to the rear muffler assembly. (MAN does it scare ya when your vette suddenly sounds like a TRACTOR and there's this nasty grinding metal noise as the muffler pipe rests on the half-shaft!)
Thread Starter
Racer
Joined: Jun 2004
Posts: 323
Likes: 5
From: Austin Texas
Originally Posted by C5Gator
Same here. Driver side went first and passenger was not far behind, changed to Stingers to "correct" the problem! 
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Pro
Joined: Nov 2003
Posts: 682
Likes: 8
From: Alexandria VA
You can add me to the last too!
WHen did you get your's done? I think I know why they put a whole new system on your.....they welded mine, but didn't line the pipes up correctly, so to make the tips look the same on both sides (which by the way they are noticably VERY uneven) they heated up my borla stingers and bent the pipes in certain areas WITHOUT asking 
I was so amd that after going back to show them and told them I would not even consider the option of them trying to fix their mistake. They will never see my car again. You would think a shop named "Corvette Specialists" would know better...
Originally Posted by bob98
According to the Corvette shop I went to, they have seen a number of these on older C-5's. Had to replace my whole system ( we put on a 03 takeoff system on my 98)
I was so amd that after going back to show them and told them I would not even consider the option of them trying to fix their mistake. They will never see my car again. You would think a shop named "Corvette Specialists" would know better...
Race Director
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From: Out Where the Buses Don't Run, Eglin AFB/ Niceville FL
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Originally Posted by C5Gator
Same here. Driver side went first and passenger was not far behind, changed to Stingers to "correct" the problem!
Instructor
Joined: Jan 2004
Posts: 152
Likes: 2
From: Pine Brook NJ
I just started a new thread about this because I couldn't find anything when I did a search (don't have much luck with the search function). Mine just broke an hour ago - passenger side flange came undone from the section coming from the H pipe. While I was under there I noticed the drivers side looks like it is coming undone too. Is it worth having it rewelded? Looks like if it is not welded to the exact right spot, the exhaust tips will be out of line. How much does it cost to have welded? Maybe I should just spring for the X Pipe.
Thread Starter
Racer
Joined: Jun 2004
Posts: 323
Likes: 5
From: Austin Texas
I paid a guy $40.00 to weld the side that was broken and reinforce the other side where it was already starting to crack and separate. I held the exhaust tips in line with the others while he was welding it.
Originally Posted by ZX-11
Is it worth having it rewelded? Looks like if it is not welded to the exact right spot, the exhaust tips will be out of line. How much does it cost to have welded? Maybe I should just spring for the X Pipe.
Safety Car
Joined: Apr 2002
Posts: 4,653
Likes: 6
From: North Royalton, OH
St. Jude Donor '06-'07
Originally Posted by Toecutter
Mine also broke. The dealer will relace it free as it is a single assembly with the cat converter and the law says they must cover it up to 80k miles.
This was a recall and should be replaced free by the dealer. Why not get a new pair of cats for your car? Easy replacement. I've also found that the muffler shops all tend to get the welds in JUST the wrong position and your exhaust tips will look like Ellie Mae's teeth when they get done with them...
Instructor
Joined: Jan 2004
Posts: 152
Likes: 2
From: Pine Brook NJ
I searched NHTSA database and could not find this recall. Could you point to where I could find info on this recall - would love to have a piece of paper in hand when I bring it to the dealer so I don't have to deal with their BS.
