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Looks like a manufacturing defect to me. I'd head into the nearest dealer and start demanding a replacement.
Seriously that should be a $25 weld job at a muffler shop.
Edit: In fact, walk into a muffler shop and say "hey, my welder's down at the minute. can you guys zip a bead onto this thing for me?". They'll assume you know this is a 5 minute job and shouldn't cost a lot.
I re-welded mine there. The part you'll have to watch out for is the bolt hole. If you weld it to much there you'll have to grind some out for the nut to fit.
You could trim down the weld that already there so your new weld doesnt protrude out so far.
A friend of mine happens to be a welder and is going to fix this and this newfound crack on the brush bar mount tomorrow afternoon. Almost didn’t catch that manifold crack! Caught a glimmer of it as I was about to reinstall the new gasket.
Have it welded, did several of mine. If you 4 wheel, it will happen often, since the cats hang below the frame rails...so if you high center the rover...it's resting on the cats...which breaks the pipe flange.
Have it welded, did several of mine. If you 4 wheel, it will happen often, since the cats hang below the frame rails...so if you high center the rover...it's resting on the cats...which breaks the pipe flange.
Yup, it happened to be last month when I was wheeling:
Have it welded, did several of mine. If you 4 wheel, it will happen often, since the cats hang below the frame rails...so if you high center the rover...it's resting on the cats...which breaks the pipe flange.
Interesting. Everything is pointing to this having happened in the past. For starters, it's on the side where the cat that extends the lowest, and the manifold-to-head gasket was tanked too. But not the driver side. I wonder if it's all related.