Roush Exhaust Blew up?

Sjay89

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All,

i installed a roush catback system a few weeks ago. I would say less than 500 miles are on the system. Yesterday as I was driving home, I heard a loud bang and I thought a tire blew. Pulled over and discovered that the exhaust pipe basically exploded? I have attached a picture. Just wondering what would have caused this. Not sure if this is even covered under Roush warranty.

IMG_20200706_163113.jpg
 

Sjay89

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Yeah, at first I thought it was a plastic bag or something melted on but its all the metal internals inside the pipe that are exposed...
 

MrAwesome987

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I'm guessing those are your problem. I'd pull the whole system and start checking things out.
 

06 T-RED S/C GT

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Just how would cats be the problem? Even if one of the OP's cats were clogged up or defective? it wouldn't cause an exhaust pipe downstream to explode, but rather from the catalytic converter and converter down-pipe section. At any rate, the Roush extreme cat-back exhaust, is designed to be ran with the stock cats in place. Therefore, IMHO, the OP should contact Roush and file a warranty claim under manufacturers defect!
 

MrAwesome987

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I'm not sure honestly, but I'd say this warrants a check up on them.

Really, it makes very little sense that this could happen, without outside intervention, such as an impact from road debris or something.
 

RED09GT

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Can you take better pictures?
Looks like you ran over a bird dipped in tar to me.
You'll need way better pictures if you want to send them to Roush, otherwise they will say this is caused by road debris.
 

06 T-RED S/C GT

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Being as the OP installed the Roush extreme cat-back just a few weeks ago and has put less than 500 miles on the exhaust since the install, It just doesn't make sense that his stock or aftermarket cats would be the cause. If anything, if it were from a clogged cat? The OP's car would've pretty much not been very drivable, to begin with along with seeing a check engine light prior to installing the Roush extreme cat-back exhaust. Such as an impact from road debris as you brought up could very well be possible, but not very likely. Therefore, I suspect once again, it's more than likely that the Roush cat-back pipe exploded due as a result from a manufacturers defect which would appear to make far more sense. That being said, it would be in the OP's best interest to submit a warranty claim with Roush!
 

07 Boss

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I don't see how this could happen with just a faulty pipe without some kind of warning sign. The car was running normally before this happened? I would think that if you had enough back pressure to explode the pipe the car would not have been running very good. There has to be more backstory to this. Were you getting on it, maybe bouncing it off the rev limiter? No lift shifting? Nothing? I would think that you would need a pretty good after fire explosion in the exhaust to do that kind of damage.
 

Dino Dino Bambino

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Were you getting on it, maybe bouncing it off the rev limiter? No lift shifting? Nothing?

I don't have the answer but I bet the OP's pants turned brown when he heard that bang. ;)
I can only think that raw fuel must have somehow found its way into the OAP.
 

GlassTop09

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I don't have the answer but I bet the OP's pants turned brown when he heard that bang. ;)
I can only think that raw fuel must have somehow found its way into the OAP.
That could indeed happen if the PCM went into a COT prevention event (catalytic converter overheat...PCM will increase fuel amount into the cylinders on the specific bank to attempt to cool the overheated catalytic converter substrate in addition to cutting ignition timing as noted by the exhaust temp inferred from the rear O2 sensor heater circuit readout of the affected cat...OEM tune set @ 1,650*F) & since the Roush catback exhaust uses resonators in mid pipe section they can trap excess fuel vapors in them (these are an expansive type of sound control.....it's in the picture just ahead of the damage) & it can flash off if the resonator got hot enough & enough free unburnt O2 was present in the exhaust to promote the "rapid expansion" as these are close enough to the cats to retain enough heat from them (cats at speed under an OEM tune put off approx 1,200*F-1,300*F but if tuned for performance can get in excess of 1,400*F-1,500*F + depending on conditions.....mine for example currently run around 1,430*F-1,450*F at speed @ FBO\cammed\tuned NA 3V thru Kooks Hi Flow Race cats....highest I've read thru a scan tool was 1,437*F) to ignite the unburnt air\fuel mix. Engine misfiring at speed can set this up as well if it is severe enough (dumping unburnt air\fuel mix into exhaust causing cats to overheat from having to burn off the excess air\fuel thus set off the PCM to go into COT prevention) but if this was the case the PCM should have set the MIL flashing......if the misfiring counts exceeded the threshold. Might check the PCM for any pending codes\Mode 6 Misfire Monitor data for any recorded cylinder misfires that could shed some light.........

The piping shows signs of overpressure from within & the materials most likely came from the Roush resonator...........

If this was the std OEM catback exhaust layout (nothing installed in mid exhaust piping post cats...mufflers are mounted at rear of car at end of exhaust piping) then this would indeed be very near impossible as the exhaust temps would have greatly dissipated by the time it got to the mufflers (next place to potentially trap any unburnt fuel vapors) but w\ the Roush catback exhaust system (or any mid muffler\resonator catback exhaust system w\ cats still being used w\ the rear O2 sensors still active so the PCM can go into COT if it deems necessary) this can occur if the conditions are right.

Not saying that this is the culprit that caused this particular instance w\ the OP's exhaust but this is possible w\ these S197's that are still running cats w\ the rear O2 sensors active w\ a resonator\muffler mounted in mid pipe section.

Something to keep in mind for those of us who are still running cats & use a mid mounted resonator\muffler catback exhaust. Also why you also should be mindful of how your engine is tuned when cats are still being used to stay out of COT. Those that are running a FF exhaust setup.......won't typically run into this....unless the rear O2 sensors are still active & COT is still active in the tune then this still "could" happen depending on how hot the exhaust is (think FI at this point) at the mid mounted resonator\muffler....

Agree w\ Mr Awesome987.....OP needs to pull & inspect all of his exhaust to get the full extent of the damage then once any repairs are made to the exhaust I would have the engine & engine management systems checked to ensure all is good.....IMHO something had to get out of spec to cause that to happen......Roush may warranty\replace this part but be prepared if they don't.

PS--For all those that like the crackles\pops from the exhaust upon decel....that's from the engine pumping unburnt O2 into a heated exhaust w\ some unburnt fuel vapors still present so don't think it's impossible.....some folks tune their cars to do this............
 
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MrBhp

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Hey OP. Didn't you buy that system second hand? I remember you saying in your previous thread that they "appeared unused". I would say they were in fact used or sat around long enough to develop some severe issues. Maybe. Some better pictures would be awesome.
 

86GT351

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Hey OP. Didn't you buy that system second hand? I remember you saying in your previous thread that they "appeared unused". I would say they were in fact used or sat around long enough to develop some severe issues. Maybe. Some better pictures would be awesome.
If that is the situation, Roush will probably not do anything for you.
 

MrAwesome987

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If that is the situation, Roush will probably not do anything for you.
Unless he can all but prove that a manufacturing defect was the cause of this, I don't see Roush doing anything for him, even if he bought it new and had the receipt. But I have never dealt with Roush customer service before.
 

RED09GT

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Besides, if an exhaust system splits open, it is usually related to the state of tune, or whoever installed it left packing material in it, or rodents moved in and built a nest. Roush can't be held accountable for that.

But...the pictures still suck so until I see a section of pipe that actually missing or split, I have severe doubts about this.
 

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