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Discussion Starter #1
I come home from school today and find my mom's taurus out of comission.

My sister says "The muffler fell off"

I'm like: "What, the car is only 3 years old!"

I sit there and think about it for a minute. I remember seeing about 6 of these
break during the summer at the dealer (all 05's, 06's, and 07's). I bend down
underneath the car and low and behold the front coverter is broken at the exhaust
(flex?) pipe. My momsays the car is out of base warrenty but I say I think its
covered under federal or califonia emissions warrenty. I have it towed to the dealer
where I work. It was under warrenty. California emissions is 7/70k. We're safe.
Its free :) I think the friggen part is over 800 dollars! I will confirm on Wednesay
when i work next. anyone else ever see this or hear of this before?

I believe ford cheapened up on their metal. Probably to compensate for the fact
that the spring costs went up when the changed the springs so they would brake
anymore.
 

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Discussion Starter #3
At the end of the main pipe (looking toward the front of the car), there is a small section of mesh material. After that mesh material comes the converter. It broke right inbetween the mesh material and the coverter.

So when looking at the car when it was broken, you would see the exhaust pipe hanging down on the ground
while the converter was still completely attached to the engine.

I thought the mesh part of it was the only thing needing replacing until i got there. The part is one hole piece. The mesh part had to be heated up to get it out of the pipe.
 

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I believe that is part of the emission system and is covered for 8 years and 80,000 miles. Check your manual. I had a Volvo fixed free after years and 50,000 miles.
 

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I believe that is part of the emission system and is covered for 8 years and 80,000 miles. Check your manual. I had a Volvo fixed free after years and 50,000 miles.
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Yup, federal emissions warranty is 8 years / 80K miles.
 

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Discussion Starter #6
Yep that sounds about right.

It's a good thing it was free too as the converter was $420 + labor.
 

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Huh...Ford changed things for the exhaust. Don't have any mesh on my exhaust.
 
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