M-Class (W163) Produced 1998-2005: ML 230, ML 320, ML 350, ML 400 CDI, ML 430, ML 500, ML 270 CDI

I can't believe it, my CAT split in 2!!!!

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Old 09-09-2004, 04:39 PM
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S60R, ML320, W211/E350
I can't believe it, my CAT split in 2!!!!

I was driving my 2000 ML320 on 101 then all of a sudden, the car started to make this HUGE horrific sound... sounded like a riced out Civic with a coffe can exhaust...

I thought it was prob my exhaust gasket, so I took the car in for service....

When they jacked the car up, I could not believe it... The cat on the driver side, split opened, very clean, looks like laser cut.. the weld looks ok, but it just split opened... Could not believe it... Dealer wanted to charge me $800+ to fix it... I took it to a muffler shop and welded that thing back!

I just could not believe it would split open like that...
Attached Thumbnails I can't believe it, my CAT split in 2!!!!-ml-cat.jpg  
Old 09-09-2004, 05:08 PM
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99 ML 320, 97 Porsche 993 C2S, 92 300E
All to common. Below are the links to my little experience with the same problem.

http://www.mercedesshop.com/shopforu...d.php3?t=93192

http://www.mercedesshop.com/shopforu...d.php3?t=92964
Old 09-09-2004, 05:14 PM
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WOW, damn, that sucks. I guess I was not the only 1. I was baffled by how it would crack too, very strange...

well, at least it sounds a lot nicer now.
Old 09-09-2004, 05:28 PM
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2000 ML430
Originally Posted by xyzpl
WOW, damn, that sucks. I guess I was not the only 1. I was baffled by how it would crack too, very strange...

well, at least it sounds a lot nicer now.
Welcome to the club. I had the same problem too. Dealer wanted 2500 to repair cause i was out of emissions warranty. Took it to my mechanic he took it down and reweld it. Good as new now. apparently the penetration on the original weld was no good. MB quility control for you.
Old 09-09-2004, 07:32 PM
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Happens all the time. Rewelding may not last either. Generally by the time they are that old and crack in two, the cats will start to rattle or clog up.
Its expensive to fix because the exhaust pieces are very expensive, and we also have to remove the torsion bars to get the cats out. That means we have to reset the ride hieght when its all reassembled. Its not a difficult job, just involves more work than doing cats on most other cars.
Old 09-10-2004, 01:26 PM
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a car that can't do the throttle reset.
how many miles do you have on the ml? federal emissions covers exhaust til 80k.
Old 09-11-2004, 01:23 PM
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happened on my 430 a few months back....covered under warranty. But oh my God...the sounds was just as you described...a poorly modded civic with a fart can exhaust

And here I thought it was a freak thing that happened to my ML
Old 09-11-2004, 06:29 PM
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Common problem with the USA manufactured cats.
The replacement ones [MB] are now made in Germany. I have not seen any
crack yet.
Cal 7/70 covers them BUT not after you weld them!!

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