First off, sorry for the long post. Both hangers on my Roush sido (offroad) exit in front of rear tire have ripped out where they were welded to the exhaust. One on the pipe and the one on the muffler. The welds are still good but the steel has torn out creating a hole in the pipe and the muffler. Being an IWS certified welder in the heavy marine construction business it looks as if the steel was heated up to much, making it thinner, brittle and weak. Not to mention the welds don't look that good, but I have seen worse. Called Roush and they said to call Moss Motors as this is where I purchased it from. Roush also said that they would let the proper people know to be expecting a call from Moss Motors about my problem so they can work something out. So I called Moss and told them the deal and they are finding out what they have to do and are going to talk with Roush so they can hopefully take care of this. Wondered if anyone else was having difficulty with this and if so, what was the action taken. I have searched on this forum and only come up with little info. I am a little upset right now considering this exhaust system was only put on in April of this year. I thought Roush made and sold quality products that was the reason I went with the Roush exhaust system. Waiting to hear back from someone from Moss Motors to hear the verdict. In the meantime, any input on this would be greatly appreciated. Thanks.

 

That kit is made by Borla. They use 304 in all there kits. We use 409 and dont have these problems.

 

I know the kit is made by Borla. Thanks for the plug Maggie rep, but I am looking to hear from people with the same problem and what was done by Roush to correct these issues if this is a recurring problem. I am not sure it is as much of a steel problem, as it appears to be more of a weld problem, using to much heat, weaking the steel in the surrounding area, as this is the only place on the exhaust system with such problem. Not bashing here so don't get mad.

 

Well due to the fact that it is 304 Stainless You will always run into that issue

 

Called Moss Motors today and they are shipping me a new Roush exhaust system to replace the bad one totally free of charge. Made me very happy to see some excellent customer service. I buy alot from Moss Motors and this made me happy to see that they do care about the customer and not just making money. Not to mention Roush is doing there part in maintaining good customer relations. Besides the performance gains, this also made my mind up to go with the Roush Supercharger(intercooled) for my truck. Now to start saving those dollars.

PS I must give credit to the magnaflow rep as he would have maybe had a potential customer if Roush was gonna be a problem. I just love the sound and the performance I get from my Roush. Maybe Magnaflow should work on that "ugly" tone and some better performance gains, then they would have more customers and not need to try to hype their product on the forum. Roush sells itself, period. Not bashing here maggie man here, just some constructive criticism. Thanks.

 

Sounds like bashing to me and I'm not even a big Magnaflow fan.

 

It's all just a matter of opinion.

 

I like the Roush exhaust system and would not mind having one (or a S-Charger ), however at nearly twice the price, does it return twice the performance, or will it last twice as long?

My point being, MF returns a lot of value for a lot folks here.

We will see how mine holds up over time.

As far as MF customer service, I broke off a bolt on a clamp on my install, and they sent me another one out.

I am curious regarding what happened to yours. Keep us posted if you can find out.

 

Roush is sending a whole new system out tomorrow. I never said magnaflow was bad just that I didn't like the exhaust note it produces or the fact that after doing some research the Roush gets a little better performance gains than others. The price was not much more considering the above and I am hoping that it lasts twice as long. Only time will tell. But as long as they are willing to replace the exhaust every time there is a problem I could care less about how long it lasts. I am getting a brand new exhaust, what is better than that???? So how did you snap a bolt??? What grade bolt was it??? Must have put the torque wrench on her a little to hard maybe.

 

-That's good, I am glad to see companies standing behind their product.

-I don't recall the specific grade, but it was the same type / manufacturer as the stock system. I can't remember the brand (It was stamped or grooved on it).

-One would think so, but my wrench maxes out at 250 in/lb or 20 ft/lb. (I inadvertently bought the in/lb wrench.) However I never checked/calibrated it.

 

Got the new kit today and the welds look much better. Also the hangers have been bent a little differently allowing more contact area to the steel creating a better and stronger connection. Very pleased with Roush and their service. Put it on and it sounds and looks great. Hopefully I will run into no problems but will keep everyone posted if I do. Keep up the the excellent customer service and great products Roush.

 

Not sure what is going on with my exhaust but on my drive from Vancouver to Los Angeles yesterday I noticed I developed a rattle that seeemed to be connected with the increase of resonance from the right pipe (sido). I haven't been all the way under there yet but I did look at the rubber hanger and it's worn bad. I mean it looks like it is sagging heavily only on that side.
I hope that's the only problem, and I'm puzzled how it got like that. Anyone know if I can pick up a replacement rubber hanger that same size a any Ford dealer?

 

A whole new system thats pretty sweet. So now you have a muffler and tips at your free hand. That could make you some nice bucks.

 

I think you'll find plenty of people here to dispute the statement hat Magnaflow has an ugly tone. It's your opinion, and you're entitled to it. Not everybody wants to wake up the neighbors when driving down the road. More customers? I'll bet Magnaflow outsells Roush on this board. Magnaflow sells itself, too. As for performance gains, I don't care which exhaust you put on a truck - if you're doing cat-back alone, all you're really getting is more sound - and sometimes better life, if you get quality stainless materials.

Let me see - $583 for Roush SIDO or $385 for Magnaflow? No brainer - Magnaflow every time.

 

Try $430 from Mike @ Woodhouse for the Roush - At least thats what it was a couple months ago.