SX4 silencer problem

[gopinathann]

Due to heavy rain my silencer got small 2-3 holes and rust is formed and the water comes from this hole instead form the exhaust. The dealer told to use it for some time and change it later which costs around 5K. I believe it is not covered under warranty since it is due to corrosion.

I thought of welding that part through one of the known mechanic, but he told that it will create problem and it will make that hole bigger and asked to change the entire set.

What are the other options to fix this ?

[akshay4587]

I had the same problem in my Accent,and it gets corroded due to condensation.
In case you do not want to get muffler replaced,you can get it welded,after removing it.
i got it done on my car,and its working perfectly fine.
though i had to pay around 700-800 bucks for welding and painting
later on came to know that Muffler costs 1.XX bucks at A.S.S

[Psycho]

I really dont know of the after market cost of the silencer but yes Akshay is right that you can weld an additional piece of metal to cover the holes for the time being will cost 500 - 800 Rs.

Make sure that you get a coat of anti rust post that.

[gopinathann]

Thanks for the comments, I will do the welding stuff.

I planned to do anti-rust coating but the service people say that they will not coat the silencer area, so I thought there is no point in doing anti-rust coating.

[ElantraGT]

Gopi, If your car is under warrenty you can see if its because of a manufacturing defect that causes silencers to rust. It might be because of a bad seam weld or the kind of metal used in the manufacturing process. I remember a scenario when Ford India did a replacement of the door panels in Ikon because it was getting rust within 1 year. It would be good if you an check with fellow sx4 owners to see if they are having this issue.

If this cannot be put on the manufaturer then i beleive welding would be the best option than a repalcement.

[Hashim]

Since that part of silencer is made of some zinc alloy it cannot be welded. If you do, it will come off after sometime making bigger hole as told by your mechanic. Same problem in my esteem too and what I do is put mseal there. It works good for few months and come off only when the silencer touches anything like speed breakers, stones etc.

[Jaggu]

I think you can patch it up with a specialized welder, but careful or you will land up with even mor hreadache After this as Psycho mentioned do a rust protection and ensure its heat resistant. This will give you another year or so.

Straight forward thing to do is run it as it is and then replace when its corroded off.

While replacing try getting a stainless steel box if possible, otherwise do a proper rust protection before fitting it. These OE boxes are notorious for rusting up early.

[harsha.cs1]

Originally Posted by gopinathann

Due to heavy rain my silencer got small 2-3 holes and rust is formed and the water comes from this hole instead form the exhaust. The dealer told to use it for some time and change it later which costs around 5K. I believe it is not covered under warranty since it is due to corrosion.

I thought of welding that part through one of the known mechanic, but he told that it will create problem and it will make that hole bigger and asked to change the entire set.

What are the other options to fix this ?

Do NOT go for welding. It will call 5-600 bucks and will fail soon enough because if your silencer is corroded, some other place will give in and you will have to patch that again and so on. It just doesnt work. I have tried and learnt it the hard way. Welding cost me Rs. 500.
Just go in for an aftermarket silencer. It will cost you around Rs. 1500 for the part and may be Rs. 100 for fitting it. But it is absolutely worth it.
The price is for the back part, where i suspect the hole is. If you go to the A.S.S., the part may cost you 5k as you mentioned.

[gopinathann]

First I will try to push the Maruti dealer to go for replacement using warranty. Otherwise I can try Mseal instead of welding as suggested by Tbhpian.