Rear Axle Recall and Muffler Issue

Just had the rear axle recall done. When my daughter came home with the vehicle from the dealership where I had the work done, the muffler was missing. No evidence of anything falling off. Clamp to the upstream pipe seems as if it was neatly removed and the hangers are there. Called the shop back and they say removal of the muffler was not required to do the job and they were stumped.

Drove back over and they tried a new story - the muffler had been stolen off the vehicle in their lot. I said "really?!" After some further thinking and trying to call the tech who did the work, there was a reported vague recollection of the tech working adjacent that there may have been a windstar with a muffler about to fall off. I ask, show me the notes and/or the muffler. Can't produce either. I do have maintenance writeup from the tech where he dutifully recorded fluid levels, tread condition, brake pad thickness, etc. No mention of any exhaust issues.

The service manager mumbled something about me going to a muffler shop and then about splitting the cost. I said no, i want it back they way I left it, and so now we are waiting for the tech to come back to work Monday to see if he can clear up the mystery.


Question - I see posts where the added axle brackets are inferring with the muffler/exhaust pipe. Could this be part of the issue? Was the tech trying to work the issue?

The modifications made to the rear axle beam, according to the recall doesn't interfere with any parts of the exaust system; take a look on the job and you will see that some metal parts has been sticked on the axle beam housing. Nothing of the exaust system has to be removed to complete the axle beam job and the muffler is located in the middle of the van.

...and the muffler is located in the middle of the van.

The exhaust then exits the right-hand side of the van, where there is a smaller secondary muffler (a "resonator", in old-time parlance). To reach the rear of the van, the exhaust pipe crosses over the rear axle right above where the dealer installs one of the rear axle reinforcement brackets. The bracket has a small, rounded cutout on top to avoid hitting the exhaust pipe. See the picture from my '00 Windstar LX:

http://good-times.webshots.com/photo/2800515210056340866TCczOc

The picture is taken from the right-rear of the van. You'll see the right-hand spring (and my Airlift 1000 spring airbag inside of it) in the upper-right-hand corner of the picture. You'll also see some of the foam insulation that expanded out of the welded axle end assembly; the dealership added the foam during the recall to avoid future corrosion problems.

Just had the rear axle recall done. When my daughter came home with the vehicle from the dealership where I had the work done, the muffler was missing. No evidence of anything falling off. Clamp to the upstream pipe seems as if it was neatly removed and the hangers are there. Called the shop back and they say removal of the muffler was not required to do the job and they were stumped.

Drove back over and they tried a new story - the muffler had been stolen off the vehicle in their lot. I said "really?!" After some further thinking and trying to call the tech who did the work, there was a reported vague recollection of the tech working adjacent that there may have been a windstar with a muffler about to fall off. I ask, show me the notes and/or the muffler. Can't produce either. I do have maintenance writeup from the tech where he dutifully recorded fluid levels, tread condition, brake pad thickness, etc. No mention of any exhaust issues.

The service manager mumbled something about me going to a muffler shop and then about splitting the cost. I said no, i want it back they way I left it, and so now we are waiting for the tech to come back to work Monday to see if he can clear up the mystery.


Question - I see posts where the added axle brackets are inferring with the muffler/exhaust pipe. Could this be part of the issue? Was the tech trying to work the issue?

Yes ... You are 100% right. My Windstar the muffler almost fell - off twice (High rattle saved me). There is a slot on the brackets but the muffler is on rubber hangers and it is not necessary that it stays right into the slot while driving. It is a stupidly designed band-aid from FORD.

The tail end pipe gets knocked hard by the rear bumper when the vehicle goes over a big bump and the rear suspension moves up. This in turn breaks the muffler.
I have cutoff the tail pipe short such that that it can now move up freely when needed without interferring with rear bumper and now it is fine.

I think every one who lives in a bumpy area will eventually have this problem sooner or later if there is a clamp installed.

Thanks. What I was calling the "muffler" is the resonator. I gave up on the dealer mystery. Ordered the a new tail pipe/resonator assembly just a moment ago. After I put it on and see if there is any interference issue, I will post back with an update.