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Old Jul 7th, 2007, 12:22 AM
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bd394
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Location: New Jersey
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DIY Cat failure w/ Milltek catback

I have had a Milltek Catback for a few years and have done at least 40k miles with the exhaust. My 2003 MCS now has 70k miles and I recently have been hearing an exhaust leak from under the car. I assumed that it was probably the flange bolts coming loose where the header/cat assembly connects to the Milltek catback. Boy was I wrong!!

It turns out that the exhaust pipe coming out of the pre-cat(?) has broken completely from the remainder of the exhaust. I assume its a pre-cat bacause there seems to be two parts to the cat, a small one and a large one. The break is between the two parts. I have attached some pics for all to see.

Any ideas what caused this? Has anyone experienced this before? What can be done to fix it? Would it be covered under the federal emissions warranty? Has there been any TSBs for this issue? Any help would be appreciated.
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2003 Solid Black MCS All options (except Nav and PDC), Milltek cat-back, red/white tailights, Whalen knob, Osram Silverstar high beam, 16" Dunlop Winter Sport M3
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