My 95 xjs 6 cyl has a ‘‘break’’ about 6 inches before the end of the
front converter.The break is straight all around (actually oblong)
in front and flaired on the other end of the break. I’m wondering,
is there a gasket that fits in here or did the last owner have the
local muffler shop do a quick repair? My local muffler shop says
it’s too thin to weld. Any suggestions are truly welcome. Thanks,
jack–
ratsass
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
In reply to a message from ratsass sent Fri 22 Sep 2006:
This is not out of the ordinary on the exhaust on an AJ16 engine.
The two down pipes join (under the heat shield) to a single pipe
via an oblong union. The weld has broken.
Locate a decent muffler shop who has stainless rods, cut the shield
and bend it back. The down pipe, union, and exit pipe are thick
enough to re-weld. Once done, bend the shield back and have them
tack it to the assembly. Not concours, but will work fine.
If the break is in a spot that they have no access to it, like
upper radius, toward the transmission and the floor board, you may
elect to have the pipe removed and re-welded.
I paid a shop $35.00 to repair mine insitu.–
The original message included these comments:
My 95 xjs 6 cyl has a ‘‘break’’ about 6 inches before the end of the
front converter.The break is straight all around (actually oblong)
in front and flaired on the other end of the break. I’m wondering,
is there a gasket that fits in here or did the last owner have the
local muffler shop do a quick repair? My local muffler shop says
it’s too thin to weld. Any suggestions are truly welcome. Thanks,
jack
In reply to a message from uncle sent Fri 22 Sep 2006:
Last year mine cracked at the joint just under the heat shield. I
got opinions from three shops that it couldn’t be welded. The
correct down pipe was 1300-1400 at the dealer depending on which of
the two you need. I went back to the shop I trusted, Cole Muffler,
and they ordered an aftermarket one from one of their suppliers in
that looks different, as no heat shield around the cats, but it was
around 7-800 installed.
Lee Murray '95 4.0 Convertible–
The original message included these comments:
This is not out of the ordinary on the exhaust on an AJ16 engine.
The two down pipes join (under the heat shield) to a single pipe
via an oblong union. The weld has broken.
Locate a decent muffler shop who has stainless rods, cut the shield
and bend it back. The down pipe, union, and exit pipe are thick
My 95 xjs 6 cyl has a ‘‘break’’ about 6 inches before the end of the
front converter.The break is straight all around (actually oblong)
in front and flaired on the other end of the break. I’m wondering,
is there a gasket that fits in here or did the last owner have the
local muffler shop do a quick repair? My local muffler shop says
it’s too thin to weld. Any suggestions are truly welcome. Thanks,
Kirbert
(Author of the Book, former owner of an '83 XJ-S H.E.)
4
LeRoy Murray wrote:
Last year mine cracked at the joint just under the heat shield. I
got opinions from three shops that it couldn’t be welded.
Somebody’s talking to the wrong welder. As long as it’s made of
metal, I think it can be welded. Most welders enjoy a challenge. I
once watched a guy weld a piece of titanium to a piece of tungsten.
I also watched two aluminum beer cans get welded together.
It might be something that could use more than a simple repair,
though, if several people are having the same problem. Maybe
somebody needs to figure out how to reinforce this area so it won’t
break open any more.
The
correct down pipe was 1300-1400 at the dealer depending on which of
the two you need. I went back to the shop I trusted, Cole Muffler,
and they ordered an aftermarket one from one of their suppliers in
that looks different, as no heat shield around the cats, but it was
around 7-800 installed.
A wise decision. If the OEM part broke, don’t just buy another OEM
part. Buy somebody else’s, anybody else’s, couldn’t be any worse
than the OEM.
In reply to a message from Kirbert sent Sun 24 Sep 2006:
The guy who welded mine was just a regular Joe, it was easy to do,
as I watched. The metal was stout.
I don’t think it is a matter of support or reinforcement, I think
it was a funtion of a poor initial weld. Perhaps it was an
automated process set wrong.
I have seen those aftermarket cats, which are probably fine, for
about $375.00.–
The original message included these comments:
Last year mine cracked at the joint just under the heat shield. I
got opinions from three shops that it couldn’t be welded.
though, if several people are having the same problem. Maybe
somebody needs to figure out how to reinforce this area so it won’t
break open any more.
that looks different, as no heat shield around the cats, but it was
around 7-800 installed.