muffler trouble

[gmader2001]

Hey everyone! Just wondering if anyone has had problems with their exhaust. At 76000kms the gasket between the cat and exhaust pipe pretty much fried. When they took it off only half the gasket was left. That was in the summer. Now at 108000kms the flange between the pipe and muffler broke. Im just wondering if anyone else has been having some problems too.

[conversation]

Yes, a few Versa owners here have reported exhaust repairs needed. The fault is said to be "road salt". But many owners said they drive through salt and have no exhaust problems.

The original equipment muffler is expensive. above $400, I think.

Did your warranty cover it?

[gmader2001]

None of the work was covered under warranty. To fix the flange it would of been at least $400 to get the part from the dealer, but the place I went to fixed the one that was broken for about $100.

[Bubs daddy]

I have yet to see any pics of these exhaust problems.

[mumsnarf]

I had posted pics in another thread titled "muffler" of the broken weld on my muffler. Two dealers wouldn't fix it under warranty, wanted $550. Got it re-welded at Midas for $80.

[conversation]

Mumsnarf,

That's good news that you were able to get Midas to weld it for way less than the dealer replacement cost.

I looked at your pics and it looks like the pipe broke right where the flange starts to flare out, right ? It was welded there? So Midas just rewelded the weld ?

Thanks

[mumsnarf]

Yeah there is a weld that connects the pipe from the muffler to the flange. The weld separated from the flange leaving it pretty clean.

The guy actually cut off the end of the pipe coming off the muffler and welded in a small coupler to the flange. It only took him about an hour.

[led hed]

a 'flangectomy'. i had one done on my previus car from midas as well.

[Atlwonderwoman99]

The muffler on my 2007 versa went out at 52000 miles. Weld came apart clean as can be even though nissan said it could have been rust. thanks for the tip on the midas rewelding job.

[fniguy]

Nissan Canada is replacing them under goodwill on a case by case basis. (i.e. if you're a good service customer or not)

[bigdaddychia]

Must be a canadian and northern thing. I still have my origiinal muffler. 260k miles and counting

[lunatis]

I have the same problem since yesterday, Nissan Versa 2008 HatchBack!

The muffler began to do a very weird sound one day, only thing I know, next day when I'm not rolling it does a much louder sound and I don't really want to make it worst, not sure I should be rolling with this...

[lunatis]

Between, I'm only at 53 000KM.

[VersaChick]

46k miles here, mine just went. Tried welding it, but it didn't hold.
No one carries the thing either!

[kam4726]

Yeah. i just got this problem fixed 2 weeks ago. Muffler pipe broke by the flange. Muffler place could not find replacement muffler and offered to cut out the flange part and create a "sleeve" type of joint by cutting a 3 inch pipe, inserting 2 ends of pipes and re-welding it permanently . They asked 100$ for it. I cruized around and found garage where they specialize in alternators:). Guy over there did the same job for me as the muffler guys would do for $50.

Dealer said 270$ for muffler just a muffler.

[sweetcera]

I'm having the same problem with my muffler/exhaust. Took it into the dealership and they said that a piece in the exhaust is made of this shotty steal material that easily erodes "naturally" with the salt mixtures they use on the roads. Really?? Unbelievable! My car is only 3 years old from when I purchased it!! Another girl came in to the dealership with the same problem with hers. They want 500 bucks to fix it. This is s***. Nissan should be recalling these suckers and replacing them with good parts. I am telling all my friends and tweeting about it. My next car is gonna be a Volvo.

[stumpsr]

Mine just went with 73000 miles. Haven't brought it anywhere and I will jump through hoops to not give the dealer a stinking penny. The rest of the undercarriage is clean. This is BS and is clearly a design flaw and Nissan should be responsible for it.

[Andrews Chalmers]

https://www-odi.nhtsa.dot.gov/ivoq/

File a report folks.

Get the NHTSA to investigate the failures - I mean if your muffler ends up on the road on the highway, it can cause accidents.

[SikBoy]

I understand everyone's frustrations with this problem. Road salt does play a major factor in the undercarriage of cars that drive within the "Salt Belt". I know because I work at a Nissan dealership in Ohio. As for them covering it under warranty, it depends on what warranty you purchased with the car. Not every piece is covered with extended warranties either. Your best bet, if you're warranty will not cover it is go to an aftermarket muffler shop and have them put a muffler on it if the weld is unfixable. Just my opinion on the matter. I see both sides of the spectrum with working here and owning one of our cars.

[Andrews Chalmers]

I understand everyone's frustrations with this problem. Road salt does play a major factor in the undercarriage of cars that drive within the "Salt Belt". I know because I work at a Nissan dealership in Ohio. As for them covering it under warranty, it depends on what warranty you purchased with the car. Not every piece is covered with extended warranties either. Your best bet, if you're warranty will not cover it is go to an aftermarket muffler shop and have them put a muffler on it if the weld is unfixable. Just my opinion on the matter. I see both sides of the spectrum with working here and owning one of our cars.

I know for me, personally? I don't expect the car to survive 15 years of rust free existence. But every time I get below the car, I made sure to inspect everything after the exhaust manifold.

I'm not sure what alloy was used for the construction of the piping & muffler, but whereas the rest of the underbody is clean and free of corrosion, the everything between the exhaust manifold, converter, and muffler is rusted.

[Billy Orbit]

52,000 miles on my 07 and I have the same weld failure at the flange..

[Andrews Chalmers]

Please report it to the link posted above!

[megpl1]

Hi I reported today.

BTW -> Midas wanted $800 for a new muffler!
I took it to the Minneke and the mechanic welded "the pipe" back to the muffler (there was nothing wrong with the muffler itself) for $150.
The pipe that connected the muffler was broken – it looked like someone cut it; a clean break.
The mechanic told me that this is 3rd Versa this week with the same problem.

[Mistymeadows]

Another problem with a 2008 Nissan muffler. Mine broke this month with 44,000 miles and something. It broke right at the weld joint. The individual that I worked with at the Nissan dealership told me that this was the norm in New England weather. The warranty will not cover it. This is ridiculous. They put a coupling on it with a couple of clamps and charged me nearly 250 dollars. They told me it would have cost 800 dollars to fix it properly. Perhaps I should have taken it somewhere to have it welded.

I have spent the money to patch it up...and now it is still making noise. I have to use a second day off to bring it back to get rid of the noise.

Last week, I called the company to see if they would compensate me to get it repaired properly, or at least pay for the repair they did do (which wasn't sufficient anyways). The person I called at Nissan company was supposedly able to make an informed decision as to whether they should pay for it. All they did was question the individual that I worked with at the dealership the day they patched it up. He told them that this was not unusual.

Given that I was a certified welder, my suspicions are that the product is deficient. The pipe should not be completely severed at the weld joint. Especially given the low mileage. And if there is that much of corrosion, I would agree the metal was not of good quality.

I am going to file a complaint. I would be interested in hearing from any others who have had this problem.

[Andrews Chalmers]

My suspicion re the weld failing is that the weld corrosion is caused by a lack of proper cleaning and preparation resulting in rusting of oxide surfaces on the muffler.

[Mistymeadows]

I received a call today from the place where I have been taking it. They indicate they will replace the muffler, but they do not want to reimburse me my 250 dollars. I am still not happy, given the low mileage. I just don't think I should be dealing with this type of thing on a car with under 45,000 miles on it.

[babytoe]

gf recently had the broken muffler flange issue..replacement mufflers are available now aftermarket for around $100, factory mufflers can be found on the web for around $180. DIY replacement is easy, two bolts and three rubber hangers. If the seal needs to be replaced they should be available locally for around $4. The repair quotes in this thread are a rip off..if you can't do the work yourself buy the part and bring it to a trusted independent shop..

[shekshishekki]

54k miles and my wife's muffler flange rusted off too. Bought a Bosal muffler for $98, $9 for a new gasket.

Does anyone know what sized nuts they use to bolt the muffler to the mid-pipe? The part number is 20020BA and none of the dealers have this in stock. Anyone know what the nut specs are? I was going to try and just go to home depot to find one.

[TijgerStrepen]

2009 Nissan Versa sedan. Muffler broke off at the flange yesterday with 57k miles. Currently seeking cat back system as replacement. Rest of the underside is nice and shiny.. Exhaust is crap.

[beacon4551]

2011 Nisan Versa 58K odm. Just dealing with this issue, muffler severed clean from the flange. How is this not a recall??