54,000 miles. 2003 Montero XLS.

A year ago I started to hear what sounded at first like lifter noise when cold, but soon realized that it was more likely an exhaust leak. I took it to the dealer and they said there was nothing wrong and that it was just valve train noise.

Well that dealer closed a month later and in the past month the noise became more pronounced. I crawl under the truck with a flash light and start poking around. To my amazment I actually spotted the problem! Viewable with just a flashlight and with out removing anything BOTH exhaust manifolds have cracks! <img src="/forums/images/graemlins/scared.gif" alt="" />

They are both at leat 2 inches long. On one the crack runs parrallel to the engine, on the other one the crack runs from the base of the middle cylinder perpendicular to the engine. I called the next closest dealership and the service adviser sounded reasuring that it would be covered under warranty but I am aprehensive, technically it the Manifolds are only covered for 50k miles, but I did complain about it before then.

Anyone have any insight as to Mitsubishi's flexibility in a situation like this?

I have to drive 55 miles to get to the dealer. <img src="/forums/images/graemlins/frown.gif" alt="" />

Uhg!

Do you have any paperwork from the first complaint?

The Monty's are notorious for cracked manifolds, specifically the driver side. My buddy just replaced the one on his 2001 and they are not cheap...like 200+ a piece. I however didnt wanna shell out that much for mine so I went down to the local AirGas store and bought me some Nickel welding rod and welded it up. Mine was cracked just about all the way around and was messing with my O2 sensors and sending a check engine light. All total...was 10$ and about an hour and half of my time to remove and re-install it. Was easy as pie and tons cheaper.

If you cant get Mitsu dealer to replace it under warranty, (which you still should persue) I would just do like I did. <img src="/forums/images/graemlins/kewl.gif" alt="" /> <img src="/forums/images/graemlins/kewl.gif" alt="" /> <img src="/forums/images/graemlins/smile.gif" alt="" />

Well, I havne't posted an update on this first because I was too mad <img src="/forums/images/graemlins/angry.gif" alt="" />, then because I got laid off and was even more mad <img src="/forums/images/graemlins/angry.gif" alt="" />. Well....

I drive the almost 60 miles to the dealer and the icehole service manager just gets my vin# and the miles, plugs it in his computer ans says, "Nope, not covered" I 'm like WTF, you couldn't do that over the phone? "I'm too busy to do that" there were zero cars in the drive, now I know why. So he starts to write up a repair ticket and I say, "Don't waste your time, I am not paying you to fix it, I'll do it myself." The look on his face was funny, he was actually shocked that I was going to fix it myself! lol.

Decided to order new manifolds from Mitsubishiparts.com, still waiting for them, should be here by friday.

$473 delivered including gaskets. Not as bad as it could have been I guess. <img src="/forums/images/graemlins/rolleyes.gif" alt="" />

Now find a job.... <img src="/forums/images/graemlins/kewl.gif" alt="" />

Good luck, the manifolds are cheaper than what I would have expected. I hope the repair goes smoothly and more importanly, that you find a job quickly.

There was one on Ebay the other day, pretty cheap..not sure if the auction is over or not. It was new.