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TDak
Dodge Dakota
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12/11/2002
17:55:16
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 Subject: Gibson Muffler internal rusting problem.
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On my 99 Dakota with a 318 I have a Gibson Cat back Dual exhaust and I have been hearing a strange sound coming from somewhere in my exhaust. It's a different sound than the traditional exhaust leak. I took it in to my muffler shop and he told me that its coming from inside the muffler. He says that what happens is the baffles inside rust and this causes the wierd exhaust noise. It's not rusted on the outside. He says he sees it all the time on Gibsons. So much so, that he doesn't sell them anymore. Wants to switch me to a Flowmaster. Has anyone else had this problem with Gibsons or is he just trying to sell me a new muffler. Also, I like the sound of the Gibson. Has anyone owned both that could give me a comparison?
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chris
Dodge Dakota
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12/11/2002
18:09:04
|  RE: Gibson Muffler internal rusting problem.
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Flowmaster will be louder inside and outside. When you wash your truck if you spray water into your exhaust pipes, that water has to go somewhere, so it turns to rust. I have a bad baffle in my flo, so it sounds different on start-up, but once it gets warm it sounds almost the same.
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CHris
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mrhotwheels
Dodge Dakota
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12/11/2002
21:23:02
| RE: Gibson Muffler internal rusting problem.
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What usually causes mufflers to rust inside is water getting trapped inside. The water is a byproduct of the catalytic converter. You have probably noticed water coming out of cars that are driving in front of you. You will notice that some mufflers have a little hole on the bottom of the muffler on the front and back right next to the seam. That is a weep hole that allows excess water and moisture to escape. In mufflers that don't have the weep holes, you can get a lot of internal rust. Also, mufflers can rust out if you only make a lot of short trips around your town. The muffler never gets hot enough to burn off the moisture that gets inside of it. I would take a hole punch and put a small hole in the front and rear off the muffler on the botom.
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TDak
Dodge Dakota
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12/12/2002
08:45:22
| RE: Gibson Muffler internal rusting problem.
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I checked the weep hole and it appears to be clear (didn't know it was there until now). I don't think I've ever sprayed water into the pipe. At least I try not to when washing. I guess my main question is: Are Gibson's more likely to do this than any other brand of muffler? I do like the sound of the Gibson, but will definitely switch if is likely to do this again.
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mrhotwheel
Dodge Dakota
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12/12/2002
16:41:07
| RE: Gibson Muffler internal rusting problem.
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Don't worry about a small amount of water being sprayed into the muffler. As soon as the muffler gets hot the moisture should burn out. Since the weep holes are fine that really should not be of concern. I have never owned a Gibson exhaust but I always heard they were kind of cheap. I know they make a stainless steel and an aluminized system. I would imagine the stainless version would not rust. I personally would never get anything but a stainless system. I can't imagine removing my factory stainless system for something of a lesser quality. Exhaust systems are like anything else. You usually get what you pay for. A flowmaster master may last a little longer than a Gibson only because the casing of a flowmaster is very thick but the but as someone else stated the plates inside still rust out. To my knowledge flowmaster does not make a stainless system. I think you should either buy a stainless system or a stainless muffler such as a Borla or an Ultraflow and have a custom stainless exhaust installed. Make sure the shop you choose have a mandrel bending machine.
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AndyL
Dodge Dakota
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12/12/2002
18:07:23
| RE: Gibson Muffler internal rusting problem.
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I have a 99 cc 318 dak and I have Gibson split rear exhaust on mine so the thing I'm wondering is yours stainless or aluminum because I live in Mn so I spent the extra cash for the stainless let a fellow dak man know thanks andy
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TDak
Dodge Dakota
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12/13/2002
12:04:44
| RE: Gibson Muffler internal rusting problem.
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Andy,
It's not stainless. At least it doesn't look like it. It just looks like regular steel. It was on the truck when I bought it used about a year ago. I know it's a Gibson though. My muffler shop recognized it.
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dogliftsleg
Dodge Dakota
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12/13/2002
20:41:30
| RE: Gibson Muffler internal rusting problem.
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and says some of you are terribly misinformed. Water is a by-product of the internal combustion engine, NOT a catylitic converter. ALL gasoline engines produce it even pre-converter models. Ask your daddys if you think me wrong. Gibson sounds good when new BUT is rather cheaply made. They use aluminized steel in those things. Aluminum is ground into a fine powder, then the steel is heated up and the aluminum is then sprayed though a special torch head to get it to stick to the steel. That is a relatively cheap way to make steel rust resistant, but not rust proof. Low cost and high profits remain the name of the game. Most stainless steels, especially the 300 series steel are impervious to rust, although the 400 series will over time sucumb to some of the acids produced durring the combustion process. However the cost of the raw materials, pound for pound is much higher then the 1000 ans 1100 series steels that are sometimes referred to as "cold rolled" and are commonly used in aluminized exhaust systems. In a salty environment, such as what those of you that live near the sea or in areas that salt the roads to melt ice and snow will see an aluminizes system or its parts last only around 2-3 years before they need to be replaced. Sometimes you don't always get what you pay for.
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knowitall
Dodge Dakota
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12/13/2002
20:56:41
| RE: Gibson Muffler internal rusting problem.
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And you say what? You did not answer any questions but instead rambled on to make yourself sound like a know it all.
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dogliftsleg
Dodge Dakota
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12/14/2002
15:06:04
| RE: Gibson Muffler internal rusting problem.
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I work in a tool and die shop and use the different steels all the time you bonehead knowitall. I can also read advertisements for products and come to a reasonable conclusion when I see the words "aluminized steel" on them as Gibson uses and was therefore based on information you have no knowledge of was telling TDak exactly why his muffler is rusting from the inside out. knowitall you once again after a pathetic attempt at flaming someone you got burned by the person you patheticly tried to flame but just could not even lite the match.
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TDak
Dodge Dakota
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12/16/2002
08:55:52
| RE: Gibson Muffler internal rusting problem.
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Well, I went ahead and got the Flowmaster Delta 40 Series put on this weekend. I looked at the interior of the Gibson after they took it off and Dog you're right - What A Piece Of Crap! Plus the Flowmaster sounds better. I don't know how they do it, but it sounds more powerful when idling, is quieter when cruising on the highway, and it freakin' roars when you stand on it. Only cost $100 installed, so I'm pretty happy about that.
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JosephAbraham
Dodge Dakota
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11/25/2006
11:18:47
| How we can prevent the rusting of exhaust systems.
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Sir,
I have a 10 year old Honda Civic, I changed the exhaust pipes and the muffler 3 times because of rusting. Is anyway we can prevent the rusting of the exhaust systems, can we coat the exhaust pipes and the muffler with rustproof coating, will that solve the problem.
Thanks
Joseph Abraham
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Kowalski
GenIII
11/25/2006
17:32:46
| RE: Gibson Muffler internal rusting problem.
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As dogliftsleg pointed out exhaust gas is corrosive, so unless you buy a system made from a decent grade of stainless steel, rust is to be expected...
Lead, follow, or get out of the way
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