Ford Fiesta Exhaust Pipe Problem Fixed

Another Day at Pellon Tyres: Broken Exhaust Pipe on a Ford Fiesta

Good morning, everyone! I wanted to share a small project we completed this week that exemplifies the kind of work that comes into our workshop every day at Pellon Tyres in Halifax. I thought it would be a good idea to write a little about this common problem and acknowledge the Fiesta’s position in automotive history when a customer brought in a Ford Fiesta with a noisy exhaust. It turns out that the poor old thing had a snapped exhaust pipe.

The Ford Fiesta is a favourite car in Britain.

The Ford Fiesta is as known to UK roads as a cup of tea is to a British kitchen, let’s face it. Since it first appeared on the road in 1976 as Ford’s response to the growing demand for compact, affordable cars, it has been a mainstay of British automobile culture. A front-wheel-drive hatchback that was affordable to operate, quick about town, and ideal for first-time drivers or families on a tight budget was somewhat of a revolution back then.

It has undergone numerous changes over the years, becoming safer, sleeker, and more fuel-efficient with every generation. From novice drivers stopping at intersections to experienced drivers utilising them for their everyday trips, you will still find them everywhere.

Unfortunately, Ford made the decision to discontinue production of the Fiesta in 2023 after more than 40 years of production. It was a really depressing day because it signalled the end of an era for the car that was once the best-selling model in Britain. However, that does not imply that they have vanished; we continue to see a lot of Fiestas here at the garage, and they are still travelling great distances.

What, then, leads to exhaust pipe failure?

Now, let’s return to our boisterous fiesta.

The exhaust pipe on this one broke right behind the flexi joint. For several weeks, the young driver had been aware of a rattling sound, but he ignored it until it became so loud that he could no longer hear his radio (or his girlfriend on the hands-free, which didn’t bother him too much!).

What, then, really leads to this kind of exhaust pipe failure?

1. Corrosion and rust
Salted roads and rainy weather are commonplace in West Yorkshire, particularly during the winter months. The exhaust system becomes clogged with moisture, which causes the metal to deteriorate with time, especially on the mid-pipe or rear box parts. If the automobile only makes short journeys, it’s even worse because the exhaust never gets hot enough to properly dry up.

2. Inadequate mountings or damaged brackets
Metal brackets and rubber hangers are used to secure exhausts. The system begins to droop or bounce if one of those fails, and the piping is subjected to further stress. Something eventually gives way, usually at a flexi or weld joint.

3. Fatigue of Flexi Pipes
The purpose of the flexi pipe is to absorb engine vibrations and permit some mobility. However, if the engine mounts are old and causing excessive wobbling, the mesh may eventually shatter or the pipe itself may split.

4. Making Contact
Even a small piece of trash or a low kerb might cause the exhaust to get out of alignment or damage the pipe, weakening it until it eventually gives way. Customers have recently caught the pipe on ramps or speed bumps in a few instances.

Our Actions – Ford Fiesta Exhaust Pipe Problem Fixed

The automobile sounded like a rally car gone bad because the break was close to the flexi area on this Fiesta and had split clear across. We gave the customer two choices: a high-quality aftermarket portion that we could weld in and save them a fair few pounds, or a genuine Ford replacement, which was a little costly.

The client chose to have the repair welded. Our exhaust specialist, Dale, welded in a new flexi pipe part after cutting out the damaged piece. In less than an hour, we had the car purring again after checking the remainder of the system and installing a few new rubbers and brackets.

A Word for the Astute – Ford Fiesta Exhaust Pipe Problem Fixed

It’s recommended to stop in for a checkup if your automobile begins to sound louder than normal or if you hear a metallic rattling coming from below. Problems with the exhaust don’t go away on their own, and the longer you ignore them, the more harm they can cause. A minor bracket problem now could result in a broken pipe tomorrow.

Concluding remarks

Working on a Fiesta always makes me a little homesick because they have played such a significant role in UK automobile culture. Both the current model with all the technology and the older Mk5s that are still going strong are fantastic small cars that are still worthwhile to have on the road.

You know where we are if yours needs some TLC, whether it’s a tyre replacement, exhaust repair or simply your MOT. Please contact Pellon Tyres in Halifax; we are always pleased to assist.