Strange exhaust problem

[wander2039]

Had a new muffler put on the Festiva a couple weeks ago. For the first week it was fine quiet as it could be even on the highway going 65mph at 3200 rpms. For the last week it seems there's times where it's 3-4x times louder. And I'm not the only one to notice it the wife mentioned it to me first. For example Friday when we drove it it was much louder.. yesterday it was fine. Friday was rainey and had strong tail winds, yesterday was a fairly nice not sure on the tailwind though.

I know this sounds weird as muffler it just a muffler. No leaks from what I can find and I checked from one end to the other. Engine runs/sounds the same. The only thing I can think of is maybe the tailpipe isn't long enough? I need to look at it again but typically it extends to the edge of the bumper I think it's a few inches short. Not sure if that makes sense either. Could get a generic tip and put on it. Taking it to TX on Wednesday so hoping to get this figured out!

 

[Boomer]

Sounds like something is opening up as the muffler heats up. Are the couplings between the muffler and the pipes tight as possible? You may also have a defective muffler with some loose internals that are moving around under heat and pressure. There are internal welds in mufflers. Some of these may not be holding allowing baffles to move about.

 

[wander2039]

I let it get hot and checked everything it was just as tight as cold. Thought about the baffles but I'm not hearing any rattling. Guess that doesn't mean anything though the baffles could be moving back and forth regardless.

 

[cjcride]

Could be a faulty muffler.

 

[wander2039]

That would be my luck. I'm going to take it back tomorrow. The wife did say she bottomed out on a steep driveway. No damage to any of the exhaust from what I can see or even the car. I wouldn't think that would be enough to "break" a muffler unless it was broke to begin with. There'd be alot of broken mufflers out there if that's all it takes. Going to hate spending another $100 to another muffler on.

 

[wander2039]

Originally Posted By: cjcride
Could be a faulty muffler.


I must say you have a nice car line-up!

 

[mechtech2]

To check for leaks, use the old trick of jamming a rag in the tailpipe, and starting the car.
Rev here up and a leak will be evident. Big leaks even more so!
You may have to do this a few times, as someone looks around.
The car will run for up to 1/2 minute or so - enough time.

If this shows no leaks, then the muffler broke internally.

 

[wander2039]

I'll do that when I get it back. They looked at and found nothing. But they did say they thought the exhaust manifold might be leaking. It's possible but I doubt it since the sound is coming from the rear. Going to take my sister's Focus hate for the dang thing to turn noisy half-way thru the trip.

 

[wander2039]

Check the exhaust manifold nothing. This morning while I was checking under the valve cover for a odd lifter noise, normal for the B3's but I wanted to make sure a bolt wasn't loose from changing the valve stem seals, it looked like the TB was leaking. I put some gasket maker on it not sure how that would effect the exhaust. I'll admit it's been fairly quiet for 3-4 days.. the day it got really bad I gave it a swift kick maybe just maybe the flex joint at the cat/downpipe came un-seated when she bottomed out. Since the Focus we were going to take shimmy's at any highway speed the Festiva it is. I can always slow down if it gets bad.

 

[wander2039]

I'm going to revive this. This car is absolutely un-drivable! I pulled the cover off the exhaust manifold and shoved a sock in there absolutely no leaks. To me, the wife and even my dad it's the muffler as you can tell where the sound is coming from. At speeds above 55mph it resonates at a level that's uncomfortable. I've driven cars with straight pipes that's more bearable. The Aspire I had them put a muffler on a month before does have a leak at the manifold but it's even quieter. I called and made a appointment again and the lady laughed at me but said they'd look at it.. I can tell I'm going to regret not paying with my credit card. This is turning out not to be my year it seems.

 

[mechtech2]

When it's that bad it will probably have loose parts that shake or can be manually moved.
This should be enough to make the store replace it or refund you the money.

That's the next step.