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Discussion Starter · #1 ·
Anyone else experience a cracked catalytic converter in their 2015? My neighbor told me that his (same car) was replaced as the dealer found a crack. That was about three months ago. I brought mine in to address the recent recall and told the dealer to check my exhaust because mine was starting to sound pretty loud, especially on a cold startup. Sure enough mine was cracked too.
 

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2008 Subaru Tribeca
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Where was it cracked at? I haven't heard of anything like this yet..
 

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2019 2.5i Limited Forester (hers) (4th Subie), 2014 Impreza Premium (mine)(#5)
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I didn't actually see it but the notes said the pipe was cracked at the converter.
So it's not the actual converter, it's the exhaust pipe where it goes into the converter. You're in a salt state - underbody washes are a necessity. The exhaust pipe WILL rust out, and sometimes it'll do it pretty fast, depending upon your local climate.
 

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Discussion Starter · #5 ·
So it's not the actual converter, it's the exhaust pipe where it goes into the converter. You're in a salt state - underbody washes are a necessity. The exhaust pipe WILL rust out, and sometimes it'll do it pretty fast, depending upon your local climate.
The converter was replaced so the crack was likely on the end on the pipe. It wasn't rust, I was under there a couple months ago. They had the converter in stock.
 

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2017 Outback, 2.5L, Auto; 2018 Forester, 2.5L, Auto (for Mama); 2005 Baja, 2.5 Turbo, Manual
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Is this on the 4- or 6-cyl engine?
 

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02 OBW 2.5 and 2012 OBW 2.5
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very common issue. I work for a well known national exhaust maker...we are looking into building this unit now for future replacement cars. I was looking at pictures of this today actually
 

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Cracked CC

Anyone else experience a cracked catalytic converter in their 2015? My neighbor told me that his (same car) was replaced as the dealer found a crack. That was about three months ago. I brought mine in to address the recent recall and told the dealer to check my exhaust because mine was starting to sound pretty loud, especially on a cold startup. Sure enough mine was cracked too.
I had the same issue (2015 Outback-4cl)...loud exhaust on cold startup that went away once the car warmed up. I brought the car in yesterday and they told me the CC was cracked. It was replaced under warrenty (extended warrenty).
 

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'13 2.5 Premium
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Got my '13 2.5 cat replaced last week.

I was in for other service and a tech noticed excess noise and traced it to a crack in the converter. I didn't see exactly where it was, I was just told it was an external crack and not something on the interior of the cat.

It was replaced under the emissions warranty. I have a PZEV - I *think* that gives me a 150k mile warranty on the catalytic converter, but since I still have less than 100k, it was replaced under the 100k mile emissions warranty.

The catalytic converter is a pretty complicated piece of steel, there are a lot of welds and a lot of places that a crack can develop. I think my assembly had cracked closer to the engine, near the manifold.
 

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So their are two pieces the front Y pipe can get cracked typically in snow country when people bust through chunky plowed Ice berms at their driveway. Thats how I cracked my Y pipe which is the section just infront of the cat. They are two separate bolt on pieces. No rust its a quick unbolt / bolt new up deal. Took me 40 minutes on my garage floor.

The cat can get contaminated if the crack is infront of it ie road grime etc in the cat. Mine I had a local muffler shop cut out the old one weld in a new one. Mine wasn’t covered under the newer PZEV regs on that old car.

My current PZEV yes it would be a warranty thing for the Cat only not the Y pipe if that was damaged.
 

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So there are two pieces the front Y pipe can get cracked typically in snow country when people bust through chunky plowed Ice berms at their driveway. Thats how I cracked my Y pipe which is the section just infront of the cat. They are two separate bolt on pieces. No rust its a quick unbolt / bolt new up deal. Took me 40 minutes on my garage floor.

The cat can get contaminated if the crack is infront of it ie road grime etc in the cat. Mine I had a local muffler shop cut out the old one weld in a new one. Mine wasn’t covered under the newer PZEV regs on that old car.

My current PZEV yes it would be a warranty thing for the Cat only not the Y pipe if that was damaged.
 

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'13 2.5 Premium
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So there are two pieces the front Y pipe can get cracked typically in snow country when people bust through chunky plowed Ice berms at their driveway. Thats how I cracked my Y pipe which is the section just infront of the cat. They are two separate bolt on pieces. No rust its a quick unbolt / bolt new up deal. Took me 40 minutes on my garage floor.

The cat can get contaminated if the crack is infront of it ie road grime etc in the cat. Mine I had a local muffler shop cut out the old one weld in a new one. Mine wasn’t covered under the newer PZEV regs on that old car.

My current PZEV yes it would be a warranty thing for the Cat only not the Y pipe if that was damaged.

As far as the PZEV warranty goes:


The cat, and other emissions items, are warranted for 100k miles. PZEV extends that to 150k BUT... I think that only applies if the vehicle is registered in a state where PZEV is required (like CA). I don't have my warranty paperwork with me right now. I thought I read that a few years ago.


In my case, the dealer replace the whole unit under the emissions warranty. Since it's a single part number, I am not sure they would be able to separate only the cat from the other parts that are welded to it. Maybe they can, I don't know.
 

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2016 Outback Premium 2.5 CVT w/EyeSight+SRVD
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They are two separate bolt on pieces.
Not so for Gen 5, at least not according to the SOA parts web site. The manifolds and catalytic converter are a single (expensive!) welded assembly:
 

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Interesting at least it removes one possible leak joint. And dealers wanted over $1000 to fix my two piece unit. $350 oem y pipe 40 minutes of my time. $150 muffler shop visit.
 

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Outback Limited 2020 Red (former 2015)
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The thing that cracks is the short flex coupling you see in the picture. Older Subies had a braided flex joint. Our newer ones have the accordion type. Mine was discovered at 120K due to wife’s complaint about exhaust smell at idle. Non-PZEV vehicles look exactly the same; the ‘cat’ is a dummy. Part price difference $600 v $1100 from online OEM discounters. Lord knows what your dealer will get you with installation. Poor design.
 

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2016 2.5i Outback, 2002 Audi S4 Avant, 1980 CB750F Supersport, 1985 Carrera 3.2
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Thought I'd chime in seeing as my suspicions over the past year were correct and I have a crack in the flex pipe as well. The red dust appears to be residue from normal moisture/corrosion build-up inside the header after the crack opened along with a mix of insulation material, not the crack itself. I can wipe it away and the crack looks "brand new" so-to-speak (I took this before wiping more off, but you can see where I initially touched the residue with my finger along the first 3 accordion sections, everything looks exactly like that when lightly wiped away). There is no surface rust anywhere else under the vehicle and the heat shield still looks brand new. Exhaust system just has the normal patina hue to it. This looks more like a stress fracture over time rather than being caused by any external corrosion.

I asked my dealer to inspect it about 9 months or 15k miles ago when I noted the exhaust was getting quite loud, but they didn't find anything (they didn't look, bolts on the heat shield have never been removed until I took them off to inspect it). Lately I have had a strong odor of exhaust fumes in the cabin while at idle and starting the vehicle is almost embarrassingly loud. I do underbody washes on pretty much a weekly basis or immediately after it snows or rains. Car was never bottomed-out and the underbody of the engine is almost spotless apart from some surface rust on various bolt heads.

Scheduled to have it inspected along with a loaner car in the meantime while they order the new manifold. 96k miles but I have the 100k warranty package so it should be covered.

 

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2017 Outback, 2.5L, Auto; 2018 Forester, 2.5L, Auto (for Mama); 2005 Baja, 2.5 Turbo, Manual
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Yes, that flex joint has to account for tolerances in manufacturing the engine and manifold, so it gets flexed a little on installation, and flexes again everytime the engine heats and cools. And it's the thinnest material, and subjected to direct exhaust heat. But every car has a weak link. I have only 20K, but I'll keep an eye on it, lots of short trips, heat cycles.
 

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2015 Outback 2.5I Limited, Wilderness Green Metallic, EyeSight, Keyless Access with Push Button Start
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Scheduled to have it inspected along with a loaner car in the meantime while they order the new manifold. 96k miles but I have the 100k warranty package so it should be covered.

Mott Power (or anyone else): Did you get your catalytic converter covered under the 100,000 warranty? Dealer just told me mine is not covered even though I have the 100K warranty; I have 97,000 on my 2015 OB. Sure enough, the Gold Plus warranty booklet says it is not covered. That was a big surprise. Dealer is quoting $1,500 to replace. I was also told that there is an 80,000 warranty for the CC, but I am well past that.
 
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