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Help with potential exhaust issue.

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Fort Worth, TX, USA
#1
My current set up is Thermal 2.5 exhaust paired with Whoosh motorsports downpipes. Thermal portion was installed March of 21 and downpipes the end of Nov 22. Have driven approximately 1500 miles since the downpipe install.

About 2 weeks ago I noticed what sounded like a metal on metal scratching sound as I came to idle at a light. It went away under throttle and then returned as I slowed down. Since then it has been hit or miss happening sometimes when it's a non aggressive drive and sometimes after aggressive driving. A few days ago I noticed a considerable amount of fiberglass on the rear window and today as I remote started it while walking up to it a considerable amount flowed out of both sets of exhaust tips for 5 to 8 seconds before rpms dropped. Upon remote start I also noticed a ticking from the passenger side that was not present on the driver.

Looking to see if anyone has dealt with anything similar or maybe have a useful starting point for trying to figure out the issue. TYIA.
 

butt_yodel

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2022 Explorer ST
#2
I don’t know about the fiberglass, but my thermals had metal on metal scraping noise intermittently too. It was the muffler hanger and the “hook” on the muffler scraping together. I moved the mufflers forward so that the bend in the hook was further away from the hanger hole.
C98026FB-C34B-4C88-8CF9-8859D815E64E.jpeg
 

OP
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Thread Starter #3
I don’t know about the fiberglass, but my thermals had metal on metal scraping noise intermittently too. It was the muffler hanger and the “hook” on the muffler scraping together. I moved the mufflers forward so that the bend in the hook was further away from the hanger hole.
View attachment 16332
I'll have to check this out as that solid bar on that thin heat shield would in my head at least make a similar sound as to what I've been hearing.
 

UNBROKEN

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#4
One of your mufflers blew the packing out. Contact Thermal or whoever you bought it from.
 

OP
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Thread Starter #5
One of your mufflers blew the packing out. Contact Thermal or whoever you bought it from.
Any thoughts on a way to test which one it may be? I know you have extensive history modding vehicles and I've never dealt with anything like this. The thermal parts were purchased from Whoosh so I'll have to reach out to Ron. Just want to have as much info for him as possible.
 

UNBROKEN

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#6
If it blew it all out you can probably tell by tapping on the case with your knuckle. Should be easy enough to find the hollow can.
 

OP
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Thread Starter #7
If it blew it all out you can probably tell by tapping on the case with your knuckle. Should be easy enough to find the hollow can.
Tried this and there is a noticeable sound difference between the two. Tried getting a picture but the phone wouldn't focus correctly with my flashlight in the exhaust tip. The driver side portion that is inside of the muffler just appears blackened while the passenger side portion looks like a frosted windshield on a cold morning. Thank you for the information.
 



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