2nd Gen Non-Engine/Transmission Rusted out Exhaust

[CMcauliffe]

I have a '99 CTD 4X4 SHORT BED , my problem is the exhaust has extremely bad rust spots ( the tail end pipe from the muffler just fell off) through out the system, two questions



1) is it normal to have an exhaust rust this bad in four years ?



2) does the DC 7yr/70000 miles warranty cover this problem



Thanks



Gerard.

 

[bmoeller]

I had the same problem on mine. One of the previous owners had re-welded the same spot before I bought it in 11/01. It wasn't worth it to try and weld it again, so it was replaced.



As far as warranty, does your ownwers manual say anything about it in there? Sometimes the emissions/exhaust are a little different that way.

 

[rmrc]

Stock Exhaust

As you can see below, I also have a 99. My stock exhaust rusted out approximately 3 months ago. Evidently the longevity seems about average.



I called Rip Rook and installed his system. Very happy with the choice!

 

[TboneMan]

I can't wait for mine to rust out so that I can justify a 4" system. (

 

[Mtngoat]

rmrc has the best advice...



Robin

 

[Mark Craig]

Rusty Factory Exhaust

Morning Guys,



You wouldn't believe me if I told you the number of customers that come our way on the Dodges because of this exact problem. Now understand we are in the exhaust business and we love the calls, but it's amazing to me how fast the Dodge system fails under normal use. It's almost exclusively the tail pipe exit from the muffler that fails, sometimes it's the entrance to the muffler but mostly the exit. We have folks that want just the tail pipe and muffler from Chrysler but when they price it and see it's approx $400. 00, they opt to get a performance system that's new from the turbo back instead of only replacing the failed sections etc.



Mark @ DPPI

 

[Rman]

I'd be willing to bet DC see's the rust as a normal wear and tear item like a drive belt, and would not cover it. Mine is rusting, in the same areas described above. Just replace it with a new one, if you plan on keeping the truck for an extended period a stainless system might be worth looking into, spendy but it lasts a bit longer.

 

[kebees4]

Mine rusted of at back of muffler a couple months ago with only 42000 miles. It wasn't even 3 years old.

 

[#2DSL]

Used OEM Muffler

I have a used muffler from a 1994 for sale. I took it of at 10000 miles and put a straight pipe on it. Will sell cheap. PM me if interested.

 

[Willys]

It appears most of the complaints are on newer 2nd gen trucks... the 94-early 98 exhausts were different... . at least the exit pipe was. My 96 has no rust problems, neither does my brothers 96 nor my parents 98. I've actually been impressed with how well the exhaust looks on ours after so much wear(230k miles on mine, lots of off-road).



then again it may be because we live in the south and are never exposed to road salt?

 

[Mundgyver]

Just for grins and giggles here, how many of these rusted, busted exhaust systems are located in states that salt the roads A survey might produce some interesting results.

 

[Rams-n-Hogs]

While you're under there checking the exhaust for rust, you might also want to look around for other important things that might be rusting. Like the brake line that's tucked into the frame, (hidden behind the fuel tank), on the drivers side. Mine rusted through and blew when I hit the brakes coming up on a stop light a couple weeks ago. Glad I wasn't loaded, and there wasn't anything in front of me. It's fixed now, line fell apart when I was taking it off. I think everything rusts worse on the East coast than it does in Alaska.



Jim

 

[KEnhoffer]

Gerard,



My 97 tailpipe rusted out first at the hangar bracket and then fell off at the muffler exit @approx. 60,000 miles. I see that we are neighbors. I had my muffler and tailpipe replaced with NAPA parts by my Branchville mechanic for a little over $300.



I also have the 7 yr warranty - this is a wear item and was not covered.



Ken

 

[CMcauliffe]

Originally posted by KEnhoffer

Gerard,



My 97 tailpipe rusted out first at the hangar bracket and then fell off at the muffler exit @approx. 60,000 miles. I see that we are neighbors. I had my muffler and tailpipe replaced with NAPA parts by my Branchville mechanic for a little over $300.



I also have the 7 yr warranty - this is a wear item and was not covered.



Ken

I thought as much (kind of hoping i would not have to shell out any money for repairs :{ )

would you mind giving me the name of your mechanic , it would be great to be able to go to someone close by and knowing that they have done this type of repair .

thanks

Gerard.

 

[Sixpack]

Re: Stock Exhaust

Originally posted by rmrc



I called Rip Rook and installed his system. Very happy with the choice!

DITTO!!!

 

[kboettcher]

There is a guy on ebay selling the 4" Magnaflow stainless system for cheap. I think that is one heck of a deal... ... now just wish my damn exhaust would hurry up and rust out

Here is the link if you want it.

 

[KEnhoffer]

Gerard,



I sent you as e-mail with the requested ingormation.



Ken

 

[y-knot]

I think alot of the problems are related to were you live. Guys in Texas, New Mexico, ect will not have alot of problems for the first 4-5 years. Where I live in the middle of the SALT belt, the exhaust system will live a much shorter life. It is no secret that all the major automobile compannies use products in there new vehicles that are less then on par with replacement pieces. The tires are all special runs that do not hold up as "normal" tires would, shocks,batteries and exhaust systems are all guilty of being on the "low" end of the quality spectrum. What I don't get, is that when these systems do fail, why would anyone replace it (exhaust system) with another "steel" system?? Why not go with a stainless steel product and not have to worry about that part of the truck again??

 

[David_VT]

white winter coat, not snow dust?

You mean all these years I've thought that white winter coating on my truck was snow dust it was really salt?



oh, I guess that explains why the exhaust system fell off and why the underside of the truck is starting to have a rust color to it... that same color seen under the carpet that was found wet for some unknown amount of time.



Does that also explain why wiring keeps being found to be green rather than copper color? Those aftermarket backup lights died from that problem...



damn, I was much happier thinking that it was just snow dust... .



Maybe someone will come up with a full body linex or other coating for us rust belt folks that is cost effective.



And I bet BPINE's truck is still showroom clean on the left coast...



LOL

 

[Mad Bomber]

Re: Re: Stock Exhaust

Originally posted by Sixpack

DITTO!!!

Do it call rip.