Anybody had any real problems with their factory exhaust system rusting? I had my 98 Expy at my dealer for tranny service and thought it would be a great time to get a really annoying rattle at idle fixed. Turns out it's the heat shield on the cat that's pretty well rusted out and banging around. Dealer says the answer is to tack weld it (of course, they can't do that...) as this isn't covered under warranty and the shield is not available as a separate part, only with the cat. I asked if my cat was bad, but no luck

Seems kinda early to me for things to be rusting out at 50k, especially for a truck that's spent most of it's life in Texas

 

Frozen,

I think the AC thing is valid. There was a post a few months back about that "hot oil popping" "boiling water" sounding noise when it's humid and the AC is on. I was finally able to get out and watch the condensation running off the rear passenger side cat. Dripping right off the heat shield.

Now to find where it starts and try to drain it somewhere else......

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2000 EDDIE BAUER EXPEDITION 4x2

• Estate Green
• 5.4 ltr
• 3:55 LS rear
• Superchip!
• Airaid FIPK
• Gibson S/S Swept Side Cat Back Exhaust
• Hellwig Rear Anti-Sway Bar
• Energy Suspension Polyurethane Front Anti-Sway Bar Bushings
• Edelbrock Performer IAS Shocks
• Mobil 1
• Xenon Super White Head and Driving Lights
• Tow Package
• Rear Load Leveling
• Moonroof
• Century Child Seat!

-->Follow Me...<--

 

I think the drain for the A/c is what made it rust out so quick as the water will drip on the Exhaust or it does on my truck as I hear it when I get out after running the A/C on the hot summer days in TN.

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2000 F150 XLT Reg. cab
4.6 Triton Engine
4x2 3.55 rear end gear
sliding rear window
automatic keyless entry
white styleside short box

 

Had to relocate the drain on the Vette too...

 

Every vehicle I've owned has had the heat shields fall off. I just took them off and left them off. The cats weren't that close to the body on any of them. If it's about 2" or less I might put it back on.