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Old Sep 29th, 2012, 08:51 PM
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HELP: Exhaust Blow R53 JCW

Hi there!

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'll try and get some pics up of it
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Old Sep 29th, 2012, 09:04 PM
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Just tried to post a pic but : " You are only allowed to post URLs to other sites after you have made 15 posts or more. "

I'm going to make another 7 post on this thread so I can post a pic so please bare with me and don't laugh!

Ok so pics:



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Old Sep 29th, 2012, 09:05 PM
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Old Sep 29th, 2012, 09:05 PM
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Old Sep 29th, 2012, 09:06 PM
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Old Sep 29th, 2012, 09:06 PM
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Old Sep 29th, 2012, 09:07 PM
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Old Sep 29th, 2012, 09:07 PM
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Old Sep 29th, 2012, 09:08 PM
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Old Sep 30th, 2012, 11:00 AM
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Thats one way around the posts number, ingenious, good job everyones not as clever as you or we would have a forum of nothing
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Old Sep 30th, 2012, 04:13 PM
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No need for the additional posts as there's no minimum post requirement to attach an image.

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Old Oct 1st, 2012, 10:15 AM
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Ahhh didn't realise I could attach an image that way

Soooo... anyone help me out with the problem in the O/P? Is it a split weld?
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Old Feb 21st, 2013, 04:41 PM
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Just in case....

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.

Hope this helps someone out.
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Old Feb 26th, 2013, 02:48 PM
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Exact same thing happened to mine today. Snapped on the joint
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Old Feb 26th, 2013, 09:40 PM
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Quote: Originally Posted by thedman85 (original)
Exact same thing happened to mine today. Snapped on the joint

If you live in the states I have a OEM 2004 manifold w/ cat. that has 20k on it for sale.

2004 MCS JCW, 15% pulley, Dinan CAI, MSD ignition & wires, Mynes V2 header, TSW rear control arms, H-sport front and rear sway bars, H-sport lowering springs, Powerflex bushings all around, modified Forge intercooler, M7 STB , ATI Damper
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