My car started making a tremendous noise on the way home earlier. Like everyone was staring loud... I've had my boyfriend jack it up stick his head under there and he said the exhaust has split at the joint where the manifold meets the Cat. It doesn't appear that anything has broken or corroded away as such, it literally has split at the junction.
My fella's a car enthusiast so knows his way around a car but he said he's never seen a joint like it before and can't work out how it's supposed to clamp together. He said it's possibly a weld thats broken, but it looks too clean a break to be that. Is there a clamp missing or something? Can anyone offer any advice or shead some light?
I realise this post is 5 months old, but just in case it helps anyone else out.
The R53 (standard S, JCW and GP models) have a design fault with the outlet manifold/downpipe/cat. I've seen quite a few of them snap and all at this same place. The break is always neat and clean, nearly as if it was machined. I've had this happen on 2 of my R53's. My standard fix is a JanSpeed replacement (I'm in no way associated with JanSpeed, they're just my preference).
When mine let go, both times there was no warning and both times there was an almighty boom followed by very loud, unrestrained exhaust noise that scared the evil right out of me. Oh, and both times I had the acceleratrix buried in the carpet when it happened.
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