Dreaded stock cat cracked

[Medicmoose]

So, I was installing my exhaust yesterday and went to take off the factory flex pipe and noticed something weird. I noticed lots of soot coming from the welded lower section of the passenger cat. I took off the flex pipe and the weld all the way around is cracked. I know there were TSBs for the 20s and I’ve had the car less than a month and did take it back to the dealership. They’re hesitant to replace and are taking about welding the cracked area. Did anyone know if this will fix it or will it just come back?

 

[2020FordRaptor]

So, I was installing my exhaust yesterday and went to take off the factory flex pipe and noticed something weird. I noticed lots of soot coming from the welded lower section of the passenger cat. I took off the flex pipe and the weld all the way around is cracked. I know there were TSBs for the 20s and I’ve had the car less than a month and did take it back to the dealership. They’re hesitant to replace and are taking about welding the cracked area. Did anyone know if this will fix it or will it just come back?

That’s not the official fix, but it is adequate and cheaper if your car was not part of the TSB.

 

[UNBROKEN]

8 years or 80K miles is the federal emission warranty for those parts. If it’s under those limits they have no choice but to replace it.
if it’s not and you have to pay for it…have a muffler shop weld it up for 20 bucks.

 

[Medicmoose]

66k on it as it sits.

 

[UNBROKEN]

66k on it as it sits.

They have to swap it…and they know it.

 

[Medicmoose]

Going back for a full replacement. In two weeks. Thank you @UNBROKEN for the heads up.

 

[n3rd]

i have a '20 and the downpipe cracked where the hanger is and my local ford said this would not be covered under warranty: "It looks like there was also an attempt to cut through it as well" per the service advisor

 

[EDWYER]

The only thing I can see what the advisor is saying is the bottom which looks like a cut, but that's just me.

 

[Mustang5L5]

Usually they crack right at the weld or in the heat affected zone. But quick search does find other threads where it looks like it cracks in that same spot with a pretty straight line

https://www.explorerst.org/threads/catalytic-converters.5041/

Edit: here’s a post on the FB groups. Same spot. Maybe email these to your service advisor