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toddkageals

Very Loud Exhaust?

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Guys,

I have a 2011 TC. I use the van primarily for trips hauling my racing karts to the track but occasionally drive it around town too. I have noticed recently that at certain RPMs and throttle positions it gets VERY loud inside the cabin. The only exhaust leak I can find is from a small hole in the front end plate of the front muffler. It's black around the hole and water leaks from here when the engine is warming up (condensation I assume). The hole appears to be there by design and is quite small. That muffler (it's in the middle of the van but I think it's considered the "front muffler" by Ford has some surface rust but I don't see anything else obviously leaking. I don't know enough about the way mufflers are made. Could this be my problem? Not sure if the water leaking from that hole and the exhaust leaking from there indicated some sort of internal problem with the muffler or not. I'd hate to spend a couple hundred bucks replacing it if it's not the problem. Also, where's the joint to disconnect that center muffler if you have to replace it?

Thanks for the help.

Todd

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You are correct that many mufflers have small drain holes to allow condensation to exit in order to prevent rusting. It is very normal for an engine to produce condensate, especially when cold. So long is it is a small amount of water, that is not a problem. Keep looking.

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I also have a 2011 and recently INTENTIONALLY removed the small "snorkle" from the air cleaner to the drivers fender. Now, at certain rpm's, it is much boomier, but the performance has improved. Is it possible that this has come loose on your air cleaner? Worth a look.

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It's funny that you say that because I have been wondering if it could be intake related instead of exhaust. I don't know about this snorkle. I'll look into it. Thanks for the suggestion. I see you are in VA. Where are you located? Also, would you mind trying something for me? If I take a rag and fold it over and hold it tightly over the tail pipe, the engine does not even slow down. Exhaust clearly leaks out somewhere but I am not sure how much leakage is normal. Would you (or anyone else) mind trying that and letting me know the results?

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I replaced the center muffler but it made no difference. When I cut the pipe loose I noticed that the flexible pipe up near the front cat is VERY soft. I could move the pipe around almost like it is not connected at the front. I'm not sure if that joint is supposed to be so soft. Anyone know? The flex pipe had a white residue all over the mesh. It looked like it had been hot.

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