Car was really loud when it started this morning! It appears the forward muffler welds just let go. Common problem? Can they be re-welded, or do I need to replace the muffler or exhaust sections? If so, please recommend a replacement unless I have to go factory (which obviously doesn't impress me at the moment!). Can the clamped bushing just forward of the muffler be separated completely? They're sort of spherical--I loosened one and it wiggled, but I couldn't get it apart. I might just need to loosen more, however--that's a job for a warmer evening and some PB Blaster!
Thanks for the help!

 

I myself would go to a reputable muffler shop and have them inspect it.
If it can be welded, it will most likely be the cheaper option compared to replacing the mufler.

 

Looks to me that it can be welded. However, it will most likely need to be removed from the vehicle to do so.

 

Thanks--I'll try that. Do those clamps eventually let go if you cut the bolts out of them?

 

Yes the ball style clamps do loosen up once they are almost completely unbolted, but with the rust on there you might have to beat on them or the pipes a little to get it all free.

 

i thought our exhausts were a lot more solid...

first time hearing this?

 

Well, there is some surface rust, but it's hard to tell if the pits are corrosion or poor welding/porosity. Certainly the base material is intact--the weld let go. I thought a good weld was supposed to be as strong or stronger than the base material. If it's just the place most susceptible to corrosion, that tells me they didn't treat the welds, just the individual components. But our 21-year-old recently-departed Volvo didn't have weld failures in the exhaust, let alone anything like this.

And the not-5-year-old driver's seat is tearing. Just seems like they skimped on materials.

Thanks to all for the help and advice.

 

For the archives, my friend was able to weld this with a gas torch. (Originally thought he'd use MIG). There's one hanger in the right rear outboard of the final muffler that's tough to get off--I ended up taking out the bracket, which is a squeeze. Rest of the R&R is pretty straightforward.

 

 

Wow--looks exactly the same. Do you know your car's history--winter, salt, etc matter? So far mine's holding, but I never showed it to an expert, though my friend's done a lot on cars. The left joint had some sort of mesh gasket in it but the right didn't--I don't know if that shows a prior repair or not--my welds looked just like yours.
Maybe Mercedes had a bunch of trainee welders in 2013?

 

That odd to fail on such a new car, I would assume theres something wrong with the engine and transmission mount causing excessive movement.

 

I'm the second owner, I don't know where it was sourced from, it was a lease return, but I've had it for almost 3 years now. I live in upstate NY and the snow and salt are horrible, so I suppose I'll chalk it up to that. One of the welds actually cracked about a year ago resulting in a slight rattle; I put off the repair since the quote was $1500 and you could barely notice it, but the other weld let go last week, so now I have to do something about it. I will check the mounts, that's a good thought.

 

Exhaust shops never paint their damn welds it pisses me off that you have to tell them ( Unless they are welding stainless) which in our case they aren't.. Once you paint the welds with high temp paint, they should never crack again even with harsh winters and salt.