Crack in the drivers side exhaust pipe -- $2k catalytic converter fix?

My '22 threw a P0430 code and since I'd had the exhaust reroute done, I took it back to the shop that did the work assuming there was a leak. They found a crack in the weld on the flange of the drivers side exhaust pipe where the pipe from the catalytic converter joins the manifold.

They only touched the Y and I agree with their assessment that a static weld on the Y is unlikely to have cracked a weld that far up the pipe plus the code didn't throw for 5+ months after, so it's likely recent damage (lots of pot holes from a heavy winter here, maybe).

Dealer is saying it's a $2k fix because they need to replace the entire catalytic converter and that it isn't covered under warranty.

Thoughts? I'm considering having the shop that did the reroute just repair the flange crack with a weld rather than fight the dealer on a warranty claim (which they have plenty of rights to deny... the truck is far from stock but I'm wondering if anyone else has had a failure on this weld) or paying for a whole new cat.

 

This is just my opinion, but if you feel you are on the hook for the repair try the weld first. Worst case you end up right where you are now. Best case it works, you clear the code and it doesn't come back. Does your private shop feel the weld will fix the problem?

 

You have modified the truck beyond the reroute (unspecified "beyond"). Dealer is all-but-guaranteed to win this one. A weld is quicker and cheaper for now and hope it fixes all, but be ready to pay more if necessary.

 

How can you claim a warranty fix if you modified the pipe? I would just get it welded, it was your modification, right?

Similar situation happened to mine. I just got it re-welded also.

Afterthought question: is the crack upstream of the cat converter? I’m wondering if they took out the hanger that they should’ve replaced immediately downstream of the last cat at the first bend?

 

Yeah, I don't have any expectation that the dealer cover it, moreso just curious if anyone else has had a crack on that weld.

 

It's on the flange of the pipe that comes off the catalytic converter, so technically upstream but the part number is the catalytic converter (which has two pipes each with a flange). I don't think it's missing a support.

Literally while typing this my girlfriend blew a tire on a pothole on our other car... so I guess I'll go deal with that. But that's how bad the roads are right now.

 

I’m not near my truck otherwise I take a photo for you- there’s a hanger on the driver side that would keep that thing from flexing maybe that caused it?

 

Damn, what an unfortunate coincidence or maybe the shop that did the modification work ham fisted with it, but that would be impossible to prove too. I’d defiantly look around for a good welder to attempt to fix.

 

Pictures would help.

 

I don't see a pic but why wouldn't they just be able to weld it? Short of like rust/rot (which doesn't sound like the issue) or an actual bad cat just weld it. Sure beats 2k and the weld will probably outlast the rest of the exhaust anyway.

I understand why the dealership won't weld it...I don't think they're right (at least from your description) for denying coverage...but if they're hell bent on fighting it, good luck getting lawyers to fight it out in a court of law. They could probably find ways to delay the case for years I'm sure...that's literally what I hate the most about dealerships and warranties - even when they're wrong - someone's ego gets into the picture, and then it's on the customer to either suck it up or fight it out in court - even if the courts would eventually be on your side anyway...it's an impossible battle.

 

I can do you one better, the dealership was kind enough to record a video: https://imgur.com/a/qq7pwRx

I still don't think the root cause was the exhaust reroute but the shitty job on the exhaust reroute is definitely what complicates the repair: they cut the flange on the Y and welded it to the output of the cat, meaning you can't just pull the cat to weld it and you'd have to weld it in place (or cut it out and weld it back in). I noticed this after they'd done the job but chalked that up as a future me problem... hello, past me.

I think I'll just pay for the repair and chalk this up as a lesson.

I'd never fight it, to be clear. I mod my truck with the expectation that dealer interactions aren't going to go my way. But if y'all piped up and were like "this is a common issue, see X Y and Z or recall A" then I might have had a longer conversation with them.

 

have them weld it. it's not a load bearing component like the frame. just need to seal up the crack.

 

mine had a small crack on the passenger side and it was covered under warrenty
seems like they had a batch of poorly welded stuff from the robot welder
warranty on cat is 80 or 85K no TSB just under " hints " on the toyota mechanic's
website . dealer actual showed me a picture of the page

 

Damn……Had the flange not been cut it would have been warranty. I could weld that in a snap for you.

 

Yeah. Right now to weld it we'd have to cut it out because there's not enough space around the flange to do it right. Live and learn.

 

I would say the reroute cause it
Look how much of the reroute is just hang out there. Compared to how the oem ran. That's putting alot of stress on the front of exhaust where it cracked. That new Longer reroute is bouncing and hanger is acting a teeter trotter fulcrum. I would get some support on that reroute pipe.