Broken exhaust manifold

[Mikemahindrah]

Hey Gang,
So this is my first post on a negative issue on my Mahindra eMax 25. I was using it today to level off some dirt. After roughly 20 minutes, the engine became extremely loud and smoke started coming from the engine. I IMMEDIATELY shut it down. After letting it cool for a bit, I checked the fluids, oil and anti freeze. I noticed the exhaust manifold is broken off where it goes into the muffler. I contacted my dealer and sent him pics. I'm a little worried as I got the "We have alot of tractors out there and this is a first" talk. He also said he'd contact his service rep to see how this would be handled. Has anyone else had a similar issue? And was it taken care of to your satisfaction? The tractor has just over 10 hours on it. (10.7 to be exact). It has been warm here int he 80's....heat wave for us. I've abused riding mowers in this kind of weather and more doing alot harder work then I was doing today. I will keep you posted on what happens next.
Fingers crossed
MahindraMike

 

[DT86]

We like pictures too.

I can only imagine them taking care of you. If they don't it would blow my mind.

 

[Thomas]

The out come event surely tell more about your dealer.

 

[DavesTractor]

Seems like what a warranty is meant for, a flaw in materials or workmanship. Sounds like a flawed manifold, this should not be a problem. It probably had a casting issue, although this is the first time I have heard about one of these breaking.

 

[Mikemahindrah]

Re: Broken exhaust manifold...Pics

Here they are.

 

[Mikemahindrah]

Update #1.....Just spoke with Service Manager and he said it would be replaced. No mention of warranty, ect. Service is "Buried" according to him, which is completely understandable at this time of the year. How long is a reasonable wait time? Working on uploading pictures.

 

[Sysop]

Anything over two weeks for a swamped shop, they need to consider new hires. That being said, some parts they don't really make "extras" of and it takes longer to get them.

Generally in those situations I stop by and chat for a few minutes once a week for 'progress reports' and to talk about the weather...

 

[DavesTractor]

Looks like an hour would do to swap out that manifold. I bet they will squeeze you in as soon as they get the part on the shelf.

 

[Mikemahindrah]

Here are the pictures. I am cautiuosly optomistic that they will come through.

 

[DavesTractor]

Mike, that is the muffler, not the manifold. 15 minutes to change that. They will take good care of you.

 

[4570Man]

Dave is correct. The manifold is fine.

 

[arrow]

Mike, that is the muffler, not the manifold. 15 minutes to change that. They will take good care of you.

Can they give him the piece so he can change it himself or does it have to be worked on by the dealership to come under the warranty provision?

 

[Mikemahindrah]

Thanks guys for your input. I'm reticent to change this part myself due to the warranty issue. I'm sure I could handle replacing the muffler. I guess the bigger question is why did it happen in the first place. If it was in fact a "casting issue" wouldnt there be more issues like this? I guess I will wait and see. The Service Rep said he will call me in the morning. So I will take it from there.
Thanks again!

 

[DT86]

There is nothing cast about a muffler, so no casting issue. It's just a poor weld, too hot or too cold, add vibration and bam! Broken weld, leaky exhaust.

 

[DavesTractor]

People should not fear turning a wrench will void warranty. Installing a big turbo and turning up the fuel, yes, that's a problem!

But warranty does cover parts and labor, so it is certainly fine to not install this muffler yourself if that is your preference. It is understandable that you bought a new tractor to avoid having to work on it. It is just sometimes easier to take the part off and trade it for the new muffler at the dealership and swap it back on then to load it up and haul it in to them, or to pay them to haul it.

The muffler probably just wasn't welded properly when it was made. I would not worry about it unless we see a trend of failures like this. So far no trend, I've not heard of one of these failing.

 

[Mikemahindrah]

Ok Guy'S Thanks again!

 

[reevesranch]

Just had an identical break where the pipe enters the muffler. The weld failed, but it provided enough collar to wire the muffler down and make it back to the barn. There is extra reinforcement where the pipe leaves the muffler, but no reinforcement where it enters. I am leaning toward having it re-welded with reinforcement rather than a new replacement. Waiting to hear back. Perhaps some dealer will alert Mahindra to a need for reinforcement at the entry connection to the muffler - too much vibration for so little material to hold the muffler on the pipe. Other than this failure, I am continually impressed by my emax 22 for the first 32 hours.

 

[DavesTractor]

Hmmm, that is two. Makes me wonder if we are going to see some more, if so then I'd say we need to look at how these mufflers are designed. A little brace or reinforcement might just do the trick.

 

[Sysop]

I can say, by the 35 series fuel line fix and some other fixes they've released that I've seen, it may not happen fast but it will happen if they see it happen enough.

I'd go the dealer route and let them replace as many as MUSA deems necessary to issue a TSB and create a redesigned part. Fixing it yourself may get the job done once and for all, but it doesn't add to the count of repairs that makes companies like these react to issues and make needed changes. Call the dealer and tell them a weld broke on the muffler and you want a new one. Take the old one off, drive to the dealer, trade it out, then go put on the new one.

If it happens every 10ish hours, then complain directly to MUSA. Any replacement you get now will be out of a different manufacturing batch than the one that came on the unit and shouldn't have the same issues. Trading out for a new one would also determine if it is a failed design an upgraded part or simply a failed weld that needed better QA checks. Either way it is best to let the manufacturer determine the proper course to continue the improvements of their products. Mahindra is growing rapidly, that means they generally make good choices on these matters.

 

[reevesranch]

Just had an identical break where the pipe enters the muffler. The weld failed, but it provided enough collar to wire the muffler down and make it back to the barn. There is extra reinforcement where the pipe leaves the muffler, but no reinforcement where it enters. I am leaning toward having it re-welded with reinforcement rather than a new replacement. Waiting to hear back. Perhaps some dealer will alert Mahindra to a need for reinforcement at the entry connection to the muffler - too much vibration for so little material to hold the muffler on the pipe. Other than this failure, I am continually impressed by my emax 22 for the first 32 hours.

Dealer says musa is aware of the muffler problem and I will have to wait for their engineering solution...and no muffler in stock...anyway dealer is 45 min away and 5 acres of grass keeps growing an inch a day. I wired the muffler down securely in two places - 17 ga electric fence wire - and it stays tight at high rpms. Not happy but otherwise I think the emax was engineered well...hit a sweet spot in the subcompact class. I have not patented this broken muffler fix.