Borla problems


9

911teo

GT Owner
Mark IV Lifetime
Jan 5, 2007
628
Surrey, UK
Gents

I have had some problems with my Ford Racing Muffler AKA Borla muffler...

Basically at first the welds that were keeping the "box" together failed. I had them rewelded but just after a few hundred miles I started hearing rattling noises coming from the exhaust system...

I put the X-pipe back on and forgot about the Borla for a while....

But now as the track season approaches (here in the UK we have strict noise limits) I decided to have a closer look at what the problem was with the Borla (it meets most track noise requirements)

With the help of David Jones at Roush/Revolve we discovered that there are some issues that point to manufacturing defects...

1. One intake pipe has not been correctly joined to the outer casing/flange (Pic 1) so that exhaust gasses have flowed past the pipe forcing all of the packing to one end (Pic 2)
2. One of the two support braces between the two internal pipes has become detached and was loose inside the casing (Pic 5) - that was the rattle. The remaining one is still attached (pic 6) but the weld is broken on one side.
3. As there is no support for the outer shell/casing, the gas pulsations combined with the extensive heat has caused the welds at the edges of the box to fail.


I know other people have experieced 3 and it's ok... I just reweld it... but 1 and 2 are an issue.

What do you suggest?

I loved how the Borla sounded. It was perfect for long journeys on the Autobahn and for the track days.

Borla claim their products come with unlimited mileage warranty...

I do not have the receipt for the purchase and I am living outside the US...

I don't want to kick up a huge fuss (and also I know the product has been discontinued) but what would you do?

incorrectintakepipe.jpg


borlapackingtooneend.jpg


DSC05139.jpg


DSC05138.jpg


Borlaloosesupportbrace.jpg


Borlabraceattachedbutbrokenononesid.jpg
 
Suggest you contact Mr. Borla.

I'm sure they'll have some good advice to cure your problems.
 
I've had two Borla mufflers fail, probably in the same manner yours did but I did not cut it open to confirm.

Both were replaced under warranty - #3 is still in the box & will stay there.
 
If that were mine and I liked it, I would pull that packing out and buy a box of coarse stainless steel wool and pack the box full and weld it back up.

You will have a better muffler for less cost than fiddling around with exchanging it.
 
I agree with Beach. You've done the hard part already. Repack it, have it rewelded from the inside out, and you will probably have the world's best Borla. I have rewelded mine on the outside seams. Who knows what my insides look like.

Howard
 
Being a Ford Racing/Borla wd, installer and reseller we have never seen this issue. We have forwarded this link to our Borla rep and they will be commenting shortly!

CLICK HERE FOR FORD RACING/BORLA FORD GT MUFFLER INSTALL & DYNO
 
I like the idea of fixing it rather that exchanging or whatever.

If the Borla rep is so kind to give us some directions and tips it would be super cool.

As I said i really liked the sound, it made me pass the noise tests and made some great 2ft long blue flames when I was on it hard!
 
Muffler

JBA HEADERS makes a stock replacement muffler for the GT. I have one on my 06 GT; so far no problems!!!:thumbsup
 
Our Borla rep asked us to post the following:

Jack;

Thank you for posting this for us. I am unable to post as of yet. This is our old muffler design that was packed with ss wool as well as the continuous strand fiberglass. We found out not too long after that the design was faulty and the packing material would break down and come apart causing more heat to be trapped, causing welds to fail and so on. The new design which came out very soon after the initial design is packed only with ss wool making it much more durable and blow out proof. 911TEO can you email me your contact information so that we can ship you a new system? My email is [email protected]. I apologize for any inconvenience with all of this. Thanks guys and as soon as I am able to post I will. Thanks again to Muscle Motors for posting this for us.

Chris Mann
[email protected]
805-986-8600 ext 270
701 Arcturus Ave.
Oxnard, Ca 93033
 
Alex Borla and company are a class act.

Richard Hille
The GT School
 
I had the same issues with my Borla muffler. I was a big fan of their products until this exhaust. The outer box welds busted. The internal piping looked like it had been cut with a torch. Their customer service actually laughed at me when I told them I did not have a copy of the receipt. They said there was nothing they could do but sell me a new muffler (at retail price)... needless to say I no longer have that system on my car.
 
I ran into the same problem with Borla customer service, but the fix (all seams rewelded at a local NJ shop) was much cheaper than shipping the muffler to Borla, even if they had cooperated. I love the muffler.

Howard
 
MMP Inc. said:
Our Borla rep asked us to post the following:

Jack;

Thank you for posting this for us. I am unable to post as of yet. This is our old muffler design that was packed with ss wool as well as the continuous strand fiberglass. We found out not too long after that the design was faulty and the packing material would break down and come apart causing more heat to be trapped, causing welds to fail and so on. The new design which came out very soon after the initial design is packed only with ss wool making it much more durable and blow out proof. 911TEO can you email me your contact information so that we can ship you a new system? My email is [email protected]. I apologize for any inconvenience with all of this. Thanks guys and as soon as I am able to post I will. Thanks again to Muscle Motors for posting this for us.

Chris Mann
[email protected]
805-986-8600 ext 270
701 Arcturus Ave.
Oxnard, Ca 93033
Click to expand...

Jack and Chris

Thank you very much for the offer. Chris I will call you on Monday and maybe with your guidance and Roush' welding skills we can save and bring back to life the muffler I have.

Thank you again for your response.... I think it goes beyond the call of duty! As I said above this exhaust is perfect for me so it would be great to have a Borla on the back of the GT again!
 
MMP Inc. said:
Our Borla rep asked us to post the following:

Jack;

Thank you for posting this for us. I am unable to post as of yet. This is our old muffler design that was packed with ss wool as well as the continuous strand fiberglass. We found out not too long after that the design was faulty and the packing material would break down and come apart causing more heat to be trapped, causing welds to fail and so on. The new design which came out very soon after the initial design is packed only with ss wool making it much more durable and blow out proof. 911TEO can you email me your contact information so that we can ship you a new system? My email is [email protected]. I apologize for any inconvenience with all of this. Thanks guys and as soon as I am able to post I will. Thanks again to Muscle Motors for posting this for us.

Chris Mann
[email protected]
805-986-8600 ext 270
701 Arcturus Ave.
Oxnard, Ca 93033
Click to expand...

Is there a way to tell if you have a "new" design. I have one installed in 2006 and another in 2008?

Thanks
Jim
 
I am running a Borla as well since 2008. Nice sound, no problems with the welding - yet (maybe due to the few hundred miles since installation). BUT since last summer (after a track day on the EUROPSEEDWAY) I have a very unpleasant resonance between 1900-2100 rpm. Does anyone have the same problem? It is a very enoying drone sound :ack which I would like to eleminate (but how?). Could it be caused by the same problem as 911teo has reported, that the intestines of my Borla are disintegrating?
Thanks
Desi
 
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My Borla is cracking at the welds as well. I just spoke with Chris Mann via the phone number supplied in the earlier post and he was more than happy to replace the part. He stated that there was indeed a design change to deal with higher than normal street driving heat (or non-stock motors). He said that there was no date stamp or way to tell old vs. new from the outside. Currently there are none in stock and it will be six to eight weeks before I get the part. He asked me to send a few photos of the cracks and shipping info via email.
 
Great Folks - my respect! That is what I name SERVICE ORIENTATION :thumbsup


Betreff: RE: Borla resonancies

"Desi;
Definitely could be the problem. What is your address and best number to reach you at? I am going to have a new muffler built for you. It will take 6-8 weeks though. Is this okay?

Thanks,

Chris"
 
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I exchanged emails with Chris @ Borla today. I am ever so grateful for the way he treated me. Rarely I have seen such committment, respect, honesty and kindness.

He turned a situation that could have been sticky into an extremely pleasant exchange.

I still think this goes beyond what one car reasonably expect from customer support. I am totally blown away. I will be a fan for life!
 
Also I feel we should all thank Jack at MMp. If it had not been for him Borla would not be aware of these problems on our cars.

It was again a class act to contact the Borla rep and make them aware, knowing that it could have been a sticky situation.

Thanks again Jack!
 
Indeed!!! Thanks Jack for your kind support :cheers

Desi
 
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