Exhaust Leaks from Flex Pipes and Catalytic Converter 57K Miles

[Seachief]

I took my 2022 ST in to my Ford Dealer for PA State and Emission Inspection and it failed. 57,000 miles. The mechanic took me into the shop and showed me that the flex mesh material around both flex pipes in the exhaust system had failed. He went out of his way to say the ST is in beautiful shape and he noted no damage or marks to the underside at all. That didn't surprise me as the vehicle has never gone offroad per se. So both flex pipes failed on their own, and are NOT covered by the standard warranties nor by the 6 year 125K ESP+ warranty I have. COST $980 to replace.

Next he showed me the left catalytic converter and noted it too was leaking exhaust and needs a full replacement. That IS covered by one of the warranties at least. They've ordered the parts and I'm to leave it at the dealer Monday to have the work done.

Has anyone else seen these flex pipes fail and need a $1,000 non-warranty replacement with no impact damage...just part failure? The Service Writer told me Ford considers them a wear part. Hmmmm.

 

[UNBROKEN]

The flex pipes are the most common failure point on the stock exhaust. Pretty much all of them will fail at some point. There are aftermarket replacements for substantially less than the Ford parts. Check out Lethal Performance.

 

[COBRA90GT]

The federal emissions portion of the vehicle warranty covered your catalytic converter ( 8 years / 80K miles - fairly well known across the industry ; the other parts of your exhaust system, not much coverage, as you discovered ).

Did winter corrosion eat away at the mesh material in the flex pipe possibly ?

 

[Wohop]

The federal emissions portion of the vehicle warranty covered your catalytic converter ( 8 years / 80K miles - fairly well known across the industry ; the other parts of your exhaust system, not much coverage, as you discovered ).

Did winter corrosion eat away at the mesh material in the flex pipe possibly ?

if his exhaust is the cause of failed emissions test then it is covered by the 8 year 80k

 

[UNBROKEN]

if his exhaust is the cause of failed emissions test then it is covered by the 8 year 80k

A cracked exhaust past the cats is not an emission component. It’s just a cracked exhaust that failed the safety part of the inspection.

 

[Seachief]

Thanks for the good info. I plan to take some photos Monday when they put it on the lift, but it sounds like the flex pipes are a very common failure.

 

[Seachief]

The federal emissions portion of the vehicle warranty covered your catalytic converter ( 8 years / 80K miles - fairly well known across the industry ; the other parts of your exhaust system, not much coverage, as you discovered ).

Did winter corrosion eat away at the mesh material in the flex pipe possibly ?

Not sure on the corrosion aspect....will possibly know little better when I take some photos when it's ack on the lift Monday. Tee car spent it's first two years in Vermont...lot of snow but there's actually way, way less salt used around all the rivers and lakes up there...lot of cinders and sand. I'm sure none of it helps...glad they caught it I suppose, I don't want CO coming into the cabin.

 

[Cdubya]

2022 should have had the revised midpipes with the flex section more forward. Interesting that these still fail also.

 

[2020FordRaptor]

I took my 2022 ST in to my Ford Dealer for PA State and Emission Inspection and it failed. 57,000 miles. The mechanic took me into the shop and showed me that the flex mesh material around both flex pipes in the exhaust system had failed. He went out of his way to say the ST is in beautiful shape and he noted no damage or marks to the underside at all. That didn't surprise me as the vehicle has never gone offroad per se. So both flex pipes failed on their own, and are NOT covered by the standard warranties nor by the 6 year 125K ESP+ warranty I have. COST $980 to replace.

Next he showed me the left catalytic converter and noted it too was leaking exhaust and needs a full replacement. That IS covered by one of the warranties at least. They've ordered the parts and I'm to leave it at the dealer Monday to have the work done.

Has anyone else seen these flex pipes fail and need a $1,000 non-warranty replacement with no impact damage...just part failure? The Service Writer told me Ford considers them a wear part. Hmmmm.

The flex pipes are known to fail on these cars. Fords prices are way to expensive, you can basically get a full cat back exhaust for that price which replaces the flex pipes.

 

[2020FordRaptor]

2022 should have had the revised midpipes with the flex section more forward. Interesting that these still fail also.

I have a 2022 and mine are starting to rattle, was hoping they fixed them but they obviously didn’t.

 

[Jeppo]

Not covered by the ESP? What else isn’t covered?

 

[hbalek]

Not covered by the ESP? What else isn’t covered?

Ford Premium Care covers most repairs but a few things it doesn't cover. I know lighting has a separate coverage.

 

[LuxST]

2022 ST here. Down pipe was cracked and flex pipe rattled. Got CVF Downpipes and 3” Thermal. I planned on replacing anyways but just to show the original was messed up. Replaced it all at around 30k miles.

 

[Wohop]

A cracked exhaust past the cats is not an emission component. It’s just a cracked exhaust that failed the safety part of the inspection.

ahh I misread, thought they failed him for emissions

 

[Seachief]

Ford Premium Care covers most repairs but a few things it doesn't cover. I know lighting has a separate coverage.

That's right. I added the additional rider for Lighting and Keys as key fobs are not covered nor are blinkers/headlamps...one of thos blinker / tailight / brake light assemblies that leaks or fails is super expensive. Looking them up:


Tail Light Assembly (Rear)

Part Number: LB5Z13405G
Supersession(s): LB5Z-13405-G; LB5Z13405B

$920.15 US MSRP
Sale price $634.90