Broken TerraFirma De-cat pipe

[Drover]

I fitted a Terra-Firma De-cat pipe at the start of August last year.

While driving along yesterday the exhaust noise increased very suddenly, I stopped and crawled underneath for a look and found that the engine pipe had broken away from the steel plate that bolts to the bottom of the turbo. It had cracked along the weld and came apart.

Not sure why it would have done this, hasn't been hit, not rusty at all and only travelled couple of thousand K's since pipe was put on.

Now I don't know if I should just weld it back together, get a new one under warranty or replace with a stronger version ?

Anyone else has experience with a Terra-Firma De-cat pipe- positive or negative ???

[Tombie]

Has it got a flex joint?

May not be large enough to handle the vibrations of Oz roads?

[Allan]

Hi Drover, only had mine on a couple of weeks, seems o.k. but I also removed the centre muffler so may be less vibration/weight on the pipe. I'll keep an eye on it when I go away in a couple of weeks and let you know. I'd go for a new pipe under warranty if I were you.

Allan

[chook73]

Hi Drover, only had mine on a couple of weeks, seems o.k. but I also removed the centre muffler so may be less vibration/weight on the pipe. I'll keep an eye on it when I go away in a couple of weeks and let you know. I'd go for a new pipe under warranty if I were you.

Allan

How do you find it with the centre muffler removed?

[Allan]

How do you find it with the centre muffler removed?

Very little noise, you can hear the turbo spool at times but not noisy. With the decat and centre muffler both gone it seems to have a bit more grunt. I did the same to the wife's TD5 Defender 90 and it's quite noisy.

Allan

[Drover]

Has it got a flex joint?

May not be large enough to handle the vibrations of Oz roads?


Hey Tombie,

It has got a flex joint, thats does seem reasonably easy to flex.

I will take Allan's idea and remove centre muffler and seek a new decat pipe under warranty.

Cheers

[justinc]

I would put the issue at possibly poor welding/ stress relieving. I haven't seen one of these pipes up close yet but as mike says a flex joint will help in removing the vibrations but that won't help poor / insufficient welds.
Stainless and TIG is the best method for high temp areas...

JC

[Allan]

Hey Tombie,

It has got a flex joint, thats does seem reasonably easy to flex.

I will take Allan's idea and remove centre muffler and seek a new decat pipe under warranty.

Cheers

I just looked at mine and it has very little stress on the pipe. As you say, the flexy pipe seems all good. Very odd. Hope all goes o.k.

Allan

[Drover]

The weld looks fine, the break is a "MM" or so beside it.

As Allan has said there does not appear to any pressure or stress on the pipe, but I guess there must be.

https://www.aulro.com/afvb/images/imported/2012/01/532.jpg

[justinc]

I still say poor material choices/ welding.

JC

[cal415]

Doesnt look good, i know what brand de cat pipe to avoid though :)

[PAT303]

The mechanic in town just takes the cat off and takes the guts out of them and refits.Works the same and the dealers are none the wiser. Pat

[Drover]

Contacted RovaCraft today who originaly supplied the pipe they have emailed TerraFirma in the UK for thier authorisation for warranty claim.

It was suggest today that it may have been caused by a broken engine mount...

Not sure how to check them ? I used a trolley jack and block of soft wood and lifted the engine. the mount stretched about 12mm and then the suspension started to lift, so I guess that they are okay ?

They look good there are no apparent marks where the fluid has drained out and the D'Fer feel normal as far as vibrations or gear sticks moving about.....

Beats me.

[Drover]

Well, Rova Craft and Terra Firma have come to the party and given a refund on the broken De-Cat pipe.

I was lucky enough to find a replacement with "Sydney 4x4 Accessories" (same guys who sponsored the AULRO gathering, Thanks to Mark for all of his help and advice in checking for possible causes to the breakage)

The replacement was also a Terra Firma, but on comparison to the broken one, the new one is certainly different.

The flex joint is nearly twice as large and the amount of weld to the top plate is significantly more.

Other difference is that where the pipe joins the flex joint and either end the pipe remains the same circumference. The broken one was flared up about 2mm all the way around.

I also followed Allan's advice and replace the centre muffler with a straight through pipe. Additionaly I wrapped the new De-Cat in a porcelain heat proof tape.

Hope it last this time.

[Allan]

Well, Rova Craft and Terra Firma have come to the party and given a refund on the broken De-Cat pipe.

I was lucky enough to find a replacement with "Sydney 4x4 Accessories" (same guys who sponsored the AULRO gathering, Thanks to Mark for all of his help and advice in checking for possible causes to the breakage)

The replacement was also a Terra Firma, but on comparison to the broken one, the new one is certainly different.

The flex joint is nearly twice as large and the amount of weld to the top plate is significantly more.

Other difference is that where the pipe joins the flex joint and either end the pipe remains the same circumference. The broken one was flared up about 2mm all the way around.

I also followed Allan's advice and replace the centre muffler with a straight through pipe. Additionaly I wrapped the new De-Cat in a porcelain heat proof tape.

Hope it last this time.

Just had a look under mine. Its the same, I think as the one that broke on yours. No problems thus far but as yet not done much driving with it fitted. I live in hope. The Puma sounds o.k. without the centre muffler doesn't it, not as noisey as our TD5 with the same modification. I am very happy with the performance improvement the exhaust change has made also. No tune yet though SWMBO is still resistant following my Subaru fever days:twisted:.Glad you got yours fixed up at no cost. I hope all is good

Allan

[Allan]

Well, Rova Craft and Terra Firma have come to the party and given a refund on the broken De-Cat pipe.

I was lucky enough to find a replacement with "Sydney 4x4 Accessories" (same guys who sponsored the AULRO gathering, Thanks to Mark for all of his help and advice in checking for possible causes to the breakage)

The replacement was also a Terra Firma, but on comparison to the broken one, the new one is certainly different.

The flex joint is nearly twice as large and the amount of weld to the top plate is significantly more.

Other difference is that where the pipe joins the flex joint and either end the pipe remains the same circumference. The broken one was flared up about 2mm all the way around.

I also followed Allan's advice and replace the centre muffler with a straight through pipe. Additionaly I wrapped the new De-Cat in a porcelain heat proof tape.

Hope it last this time.

Just had a look under mine. Its the same, I think as the one that broke on yours. No problems thus far but as yet not done much driving with it fitted. I live in hope. The Puma sounds o.k. without the centre muffler doesn't it, not as noisey as our TD5 with the same modification. I am very happy with the performance improvement the exhaust change has made also. No tune yet though SWMBO is still resistant following my Subaru fever days:twisted:. Glad you got yours fixed up at no cost. I hope its all good. Double post, still asleep:o

Allan