Gotta love diagnosing car problems.

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You never really 100% sure what you're going to find.

My Focus, shortly after I bought it, started developing what I thought to be an exhaust leak. However since winter weather rolled in and the leak did not seem to be big I just let it be. During the course of winter the leak seemed to get slightly louder and really noticeable at idle and low revs. It looked to me that it was coming from the front of the car. I feared the exhaust manifold would need replacing.

Fast forward to this weekend and I decide to finally find where the leak is coming from.
I had a bit of seafoam left and thought it would be perfect to use for this application. Any leak should be clearly visible with the white smoke that seafoam emits.

After sucking up some seafoam and waiting about 10 minutes, I start the engine and rev it slightly. Lots of smoke comes out the back. I think "great, now I will find the leak for sure".
I crawl under the car and start inspecting the exhaust, staring from the manifold. I can't see any leaks. I rev the engine some more to force the exhaust gasses, but I still see no leaks. I check the exhaust portion after the catalytic converter, even though it was done by the previous owner last year, but everything checks out. No leaks, so it's a good thing, but now the question is: "Where is the exhaust leak sound coming from?"

I shut the car off and let it cool down. After everything is safe to be touched, I start poking around the exhaust manifold area. Everything looks good, but I notice that the heat shield on the manifold moves a bit when I pry on it. Turns out that lower mounting bolt no longer held the shield in place because there was no more sheet metal left around the bolts due to rust. I decide to remove the heat shield altogether since it will be just a matter of time before two other mounting bolts loose their grip due to rust and vibrations.

After the mandatory test drive the exhaust leak sound is gone. The shield must've had just the right frequency to sound like an exhaust leak and it never made that metal on metal sound. It even followed the revs up to 2k RPM. That is why I was certain I had an exhaust leak.

Please share your stories of misinterpreted problems that you or your mechanic experienced.
 
You might want to either replace it or get big washers to remount that heat shield. It actually slows quite alot of hear from the upper engine compartment.

I had a car I worked on that made screeching squeak when the heat or air was turned on. I opened the hood and low and behold It was a squirrels nest was inside the fender well (it was seldom used and person who owned it lived in a wooded area)!! Apparently when the fan was turned on the vibration from it shook the nest enough to make noise.
 
Originally Posted By: Propflux01
You might want to either replace it or get big washers to remount that heat shield. It actually slows quite alot of hear from the upper engine compartment.


I saved the heat shield, so I will probably put it back on. Thanks for the advice.
 
It's definitely a Ford - heat shields are falling off!

I have one falling off on my 2 year old Focus. Our F350 lost them after a year (they rusted off) and I lost one of them on the Taurus going down the highway at 70.

Typical ford issue.
 
Same think happened on my 02 Accord. It was right under the passenger seat. Took it out and had no problems.
 
Our 02 Focus still has the original shields in place but I'm sure it has a exhaust leak. Lowered the engine too low when I changed the timing belt. On the Escape I used the biggest vice grips I had and crimped it to stop the rattling. Wouldn't say a Ford issue as the Escape is the first one I've had to mess with.
 
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