Loose baffle in muffler at 40k

[Summers22]

Well just turned 40K and cold start yesterday had a loud rattle from the muffler. Pushing on the muffler driver side upward and the rattle nearly goes away. No loose heat shields. I have seen several posts on Google about this. Reached out to service advisor and they said get ahold of my salesman for a possible free diagnosis. I already know it wont be taken care of. So my options are another oem muffler at almost $400, a Magnaflow direct fit for $120 or a mallet and pound in that area to possibly crimp the loose baffle. Never had an OEM muffler fail.

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[Quashish]

never heard of that either with OEM exhaust. i got our factory muffler in storage. i doubt you're nearby though.

 

[Summers22]

Thanks but Im in Kansas. What did you replace it with? Google shows quit a bit of failed mufflers, even on the full-size Bronco.

 

[CactusBS]

Same thing happened to me, almost identical location. I was quoted $1200 plus labor for an OEM muffler install. I haven't pulled the trigger on an aftermarket one yet but that's probably the route I would go.

 

[Summers22]

Any suggestions for replacement besides OEM? I'm considering the Flowmaster FX, Magnaflow or MRT axle back. Just dont want it very noticeable in the cabin.

 

[Quashish]

I got the MRT which is nice has a low grumble. Although mine and another member here both experienced the same issue with the flanged end that is supposed to fit over your factory pipe and clamp down did not slip over the factory pipe. The supplied clamp didnt even fit over the flange either. I made it work. And will probably weld it at some point

 

[BLUEOVALRACER]

Well just turned 40K and cold start yesterday had a loud rattle from the muffler. Pushing on the muffler driver side upward and the rattle nearly goes away. No loose heat shields. I have seen several posts on Google about this. Reached out to service advisor and they said get ahold of my salesman for a possible free diagnosis. I already know it wont be taken care of. So my options are another oem muffler at almost $400, a Magnaflow direct fit for $120 or a mallet and pound in that area to possibly crimp the loose baffle. Never had an OEM muffler fail.

Magnaflow sells a direct fit Muffler for $120.00 if so I would go that route?.

 

[Summers22]

Yes, I like that one, but I mispoke, its actually a Flowmaster FX. It'll have to be welded or possibly clamped, then a couple turn down tips added. That appears to be the most affordable option.

https://www.flowmastermufflers.com/products/exhaust/mufflers/flowfx_mufflers/parts/72206

 

[BLUEOVALRACER]

Yes, I like that one, but I mispoke, its actually a Flowmaster FX. It'll have to be welded or possibly clamped, then a couple turn down tips added. That appears to be the most affordable option.

https://www.flowmastermufflers.com/products/exhaust/mufflers/flowfx_mufflers/parts/72206

Yeah that would be Your best bet at $120.00 IIRC the Flowmaster FX Cat Back is over $500.00 and doesn't give you much more besides the clamps and tail pipe tips. I had that on the 2023 BS BB I had at idle it sounded good but had to much drone IMO when driving it.I ended up taking it off returned it and put the stock muffler back on it.

 

[Stircrazy]

were you recently on gravel roads? I find I get the same thing, had it checked out by ford and they found a bunch of gravel inbetween the heat shield and the muffler and it would make a rattle that soundsed like somthing was broken in the muffler. I find it clears its self eventualy, but that might be somthing to check for, unless you really really want that new muffler

 

[Summers22]

No gravel roads and no, I want the quiet stock exhaust.

 

[TheX]

I want the quiet stock exhaust.

#metoo

 

[Chiefthepup]

Yep me too. Been intermittent for a few months. I’m just under 30k. Notice it mainly happens if idling for longer than 5-10 minutes
Hasn’t done it for a while so I’ll deal with it once it’s more permanent

 

[Summers22]

If the dealer won't replace it, Im thinking a few blows with a 3lb hammer as an experiment is worth a shot...lol

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