Engine/Transmission (1994 - 1998) Down Pipe Broke

[JWashburn]

This is regarding the '97 in my sig.



The 4" down pipe broke at the flange. Based on how I use the truck I suspect that its a vibration/work hardening problem.



I was considering installing some 4" stanless flex from the new down pipe to where the exhaust goes horizontal. This would eliminate much of the torque on the flange from the exhaust system. Has anybody done this? Any other solutions?



What do y'all think?

 

[CCiatteo]

This is regarding the '97 in my sig.



The 4" down pipe broke at the flange. Based on how I use the truck I suspect that its a vibration/work hardening problem.



I was considering installing some 4" stanless flex from the new down pipe to where the exhaust goes horizontal. This would eliminate much of the torque on the flange from the exhaust system. Has anybody done this? Any other solutions?



What do y'all think?

I had the same thing happen on my 97, and upon closer inspection it was an inferior TIG weld at the joint where the down pipe meets the adapter flange at the rear of the turbo housing. Could be something to check? I had mine re-welded and its been fine ever since. Turns out the original weld didn't bite into both pieces, but instead was almost entirely on the down pipe and had very little penetration onto the adapter flange.



Good luck

 

[JWashburn]

Chris,
its possible. What I forgot to mention is that the rear hangers have broken several times. They work harden and then snap. I spend a lot of time on dirt and gravel roads, and in the summer one in particular. The one is always washboardy. You either drive it at 5 or 50 mph. I have neither the time nor the patience to drive it at 5mph. It loosens bolts. At least every other week I take a tour underneath checking for loose bolts.

Note to self: check engine mounts in the morning.

 

[JWashburn]

Chris,

I pulled the flange adapter off the back of the turbo, and it was the weld that let go. There appeared to be no weld penetration on the flange. I also discovered that the hanger off the back corner of the transmission was gone. Thanks.

Jeff

 

[CCiatteo]

Chris,



I pulled the flange adapter off the back of the turbo, and it was the weld that let go. There appeared to be no weld penetration on the flange. I also discovered that the hanger off the back corner of the transmission was gone. Thanks.



Jeff

Happy to help... .

 

[Dave M]

The same thing happened on my 97 4 in MBRP exhaust. It broke at the flange and looked like a bad weld. It also boke at the other end of downpipe where a hanger rod was welded to the side of downpipe to hang it in a bracket on trany mount. The hanger rod ripped a hole in side of pipe probably after the weld on other end broke.



MBRP replaced it free since I was just under the 5 year warrenty for my T409 SS. Now they guareentee them for life. Here are some pics:

 

[JWashburn]

The same thing happened on my 97 4 in MBRP exhaust. It broke at the flange and looked like a bad weld. It also boke at the other end of downpipe where a hanger rod was welded to the side of downpipe to hang it in a bracket on trany mount. The hanger rod ripped a hole in side of pipe probably after the weld on other end broke.



MBRP replaced it free since I was just under the 5 year warrenty for my T409 SS. Now they guareentee they for life. Here are some pics:

From the pics, its essentially the identical failure.