When I pulled the Subaru in to take the winter tires off and wash the undercarriage I heard the unmistakable sound of a muffler leak. I was a bit surprised, as the car is only 5 years old.
I looked at the muffler, and it looked like it was in good shape, until I saw the weld where the inlet pipe enters the front of the muffler. The weld was rusted through, but the muffler itself was fine. Replacement mufflers from Subaru are very expensive. Aftermarket mufflers only seem to last two or three years. I have had great difficulty having the “lifetime warranty” honored with premium aftermarket mufflers. Even quality aftermarket mufflers do not last as long as factory ones. Many mufflers are replaced due to rusted welds and flanges.
I have replaced rusted flanges and joints, and repaired rusty welds and had the muffler last longer, than a replacement after-market muffler would have lasted.
I just couldn’t replace a muffler that was still in such good condition, so I cleaned up the area with the broken weld, and re-welded it. Now, let’s see how long this repair lasts…