Hole in my Figo's muffler: What to do until Ford gives me a new one

The vehicle is sounding like a racecar and the service centre has no idea when the replacement would become available.

BHPian ranjitp1 recently shared this with other enthusiasts.

I have a 2010 Ford Figo petrol that has done 1.4 lakh km. The car is still doing fantastic. The muffler has developed a hole now, due to which it now sounds like a racecar. The ASC obviously does not repair silencers, they only replace them. They placed an order with Ford Chennai for a replacement, but it is a back order and they have no idea as to when the part would become available, it could take weeks or months.

In the meantime, I am not sure which option to go with:

• Leave it as is and continue with the sound, however, at times it feels like the ignition is going to shut down and then suddenly it turns itself back on. Any issues that I might run into if it is left as is till the replacement is done?
• M-Seal the hole and see if it holds. Does M-Seal really do the work?
• Weld the hole, but I hear that welding increases the corrosion etc.

Any recommendations that people might have are more than welcome.

Thanks in advance.

Here's what BHPian vrprabhu had to say about the matter:

I faced a similar issue.

M-seal is only a temporary fix. Welding is easier said than done. In all probability, while removing the silencer, there is a likelihood of fresh damage to the rusted parts - as your car is nearly 15 years old and the mileage on it.

Best option is to scour for a new silencer, it should help you to clear FC renewal without any hassle.

Here's what BHPian Geo_Ipe had to say about the matter:

Cannot close a rust hole in the silencer with M-seal.

Welding is the option to go by, and will work out cheaper than a new silencer. You'll need to find a good independent garage to get things like these done if you're planning on retaining the car.

Here's what BHPian tharian had to say about the matter:

The easiest option is to weld it. But it is going to be tricky since the hole is on the top. The 2010 models had one single pipe from after the cat-con all the way to the tail pipe, which included the muffler.

If you were in Bangalore, we could have worked out a deal since I have a 2010 petrol Figo exhaust system with me since I sold my car with a free-flow exhaust.

Here's what BHPian scorpian had to say about the matter:

Weld the hole, apply a rust converter to the entire silencer, and then apply high-temperature paint.

Exhaust will last for another 15 years.

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