2003 Nissan Pathfinder "Cracked exhau...
Andy

Miami, FL

#144 Mar 16, 2009
03 Pathfinder LE 45K mi. Original owner and obviously driven very lightly. Experiencing loud engine muffle from underneath front seat area. Took it to Midas and saw for myself (underneath the car) the exhaust leaking from the cracked seam. These "resonators" are indeed oval-shaped and some genious at Nissan thought a robotic weld would be a great idea, especially since they won't ever get wet... Midas and Nissan are asking $1500-$1800. Yikes!

I'm not daring enough to do it myself, but I have a shop willing to install. I want to order the front "Walker" kits. Can someone please tell me exactly what parts I need to order (i.e. front drive/pass resonators, gaskets, etc...)

Thanks.
Nick

Chicopee, MA

#145 Mar 20, 2009
They're not catalytic converters. They're some form of resonance chamber. Min has been patched 4 times as Nissan refuses to replace the pipes. Nissan paid for the patches since the problem started during the warranty period. This is only a temporary fix and now that the warranty period is long gone, they refuse to pay any further (who saw that one coming?) Well they're leaking again. I'm waiting for a lawsuit as this is clearly a design defect. Even the dealer stated they were replacing these pipes constantly until they came up with the fantastic fix that doesn't last...
Nigel

United States

#146 Mar 30, 2009
My wife has a 2003 Pathfinder that had this same exhaust leak. I did the repair myself in about 2 hours. As stated before, the leaking pipes are not the cats. The culprits are the resonators.
RockAuto has the Walker replacement part.
#53463 passenger side resonator
#31397 flange gasket
#31311 flange gasket
#534464 driver side resonator
#31397 flange gasket
#31311 flange gasket
To remove the bolts on the upstream flange (on the cat) you will need a 14mm socket and extention. Reuse these. The nuts on the down stream end are 14mm but rust away and become irregularly sized, so you may need to cut them off. Then just use nuts and bolts to secure the new parts. You will need a 7/8" wrench to remove/install the O2 sensors. To get clearance to remove the old resonators once unbolted, loosen and remove the 12mm bolts from the bracket holding the rear exhaust pipes to the frame of the truck.
Walker Replacement Parts

Phoenix, AZ

#147 Apr 3, 2009
I ordered the walker replacement parts from Rockauto after I went to a local shop to get them to look at my cracked resonators.

They could replace them with 18" glass packs for $80 each. They checked with dealer for OEM parts, and they wanted $890 JUST FOR THE PARTS.

I opted for the walker exhaust parts online, and got them shipped to be for about $185. Muffler shop cost $100 to install, and took 40 minutes.

All is quiet now.
Andy

Miami, FL

#148 Apr 3, 2009
I just ordered all 6 parts myself and have a mech that will install for me. I've read a bunch of people mentioning they had to cut some bolts so I thought I would just buy all new bolts as to not to inconvenience the mech so he can get it done with least hassle. Can someone please tell me how many and what size/length nuts/bolts? Thanks guys! I'll post after install completed.
Ross

Decatur, GA

#149 Apr 7, 2009
Have the same issue. 2003 Pathfinder LE, Engine Light has remained on/off for some time. When read spits out p0420. First time it was tested, passed emissions and light was reset. Had it looked at today, mech. said I needed a new Cat and said he would do it for $1,145 (front passenger side). Obviously I am not going to take him up on his generous offer, but is this Walker kit what I need for the above issue? Seeing as though it has passed emissions, I am tempted to leave "as is" except for the increasingly god-awful exhaust rattle. Was told driver-side looked ok, but am I better buying parts for both and finding a local mech. to install both?

Definitely interested in any/all positive experiences with Walker and the DIY route.

Thanks.
Andy

Toronto, Canada

#150 Apr 9, 2009
2005 Nissan Quest, 3.5S, 95K km, extended warranty, same problem cracked resonators. My friend has fixed his 2003 Pathfinder resonator by welding it, it has lasted perfectly now for 4 years.
My extended bumper-to-bumper warranty does not cover resonator crack. Charge in Canada is ~$700 to replace by the dealer.
I have read some other posts on Nissan Quest about same problem with resonator. I also had a cracked heat shield bracket (there is a TSB on it).
In general, seems like Nissan's weakness is exhaust just like Ford's is transmission or GM's head gasket.
Andy from Fri April 3

Miami, FL

#151 Apr 16, 2009
Thought I'd post my results - awesome! Had a muffler shop mechanic install both left and right sides for $100 which probably took him 1-2 hours and purchased them at RockAuto for $190. Final price under $300! Midas wanted $800 to replace one side or $1500 for both. Nissan wanted $2000. Talk about getting screwed... No more loud rumbling exhaust sounds coming from under the front seats! Thanks to this forum and the guys who contributed their input I saved a ton of money and time!
Chris

Washington, DC

#152 Apr 28, 2009
I have a 2002 Pathfinder with the same problem as everyone else. It has over 100,000 miles so dealing with Nissan is not an option for me. Thanks to all who provided information on the parts from Walker. If anyone hears of a lawsuit, I am in. I will still leave my comments with safercar.gov to voice my concern.
rama K - Dallas

United States

#153 May 13, 2009
I have 2003 nissan with resonator problem. Failed state inspection. Dealer asked for $1200. Went to
Pronto Brake & Muffler Center 1800 N. Central Expressway Plano, TX 75074 test33.
www.prontomufflerandbrake.com/
They fixed under $200. Problem fixed in 30mins. state inspection passed. End of the problem. Hope this helps other.
Tom

United States

#154 Jun 29, 2009
Hello, I recently did a google search for "bad catalytic converter" on my 03 Pathfinder and was stunned by what a have stumbled across here!! I particular post #116 from Megan. I too have 3 young children (all under the age of 5) and one has very severe asthema.

I am curious what is the latest with this and if the EPA has ever gotten back to anyone about this. I am just approaching my Nissan dealer about this now and thus far they have been cordial but I am afraid what my lie ahead. Any help or feedback that anyone can provide me with would be wonderful (including contact people you have spoken to at the EPA in Washington). Thank you for your help.
Tim

Overland Park, KS

#155 Jul 2, 2009
2003 Pathfinder LE: Very noisy. Took it to Midas. They wanted $800 to replace the rear catalytic Converters on both sides. got a second opionion and he said it didn't sound like a Cat Converter at all to him but maybe a mini-muffler (whatever that is).

Finally took it to a local Muffler shop (Muffler Doctor - Kansas City). They said it was a seem on the Resonator. Replaces for $137.

Awesome!
Chris

Seattle, WA

#156 Jul 26, 2009
Did the same as Andy above - bought the resonators and gaskets from Rockauto.com ($190 w/ shipping) and took them to a shop so they could do the hardy work of cutting the rusted bolts ($100 labor +$15 for new bolts).

My Pathfinder now sounds quieter than I ever remember, and that pesky "Check Engine" light is now off (I already knew it was an oxygen sensor alert...makes sense now).

Thanks to above commenters - saved me a lot of work and money.
Tanya

Oklahoma City, OK

#157 Aug 7, 2009
Can anybody confirm that when your check engine light came on and you took it to the dealership/mechanic that their machine did in fact state it was catalyst bank 1 and bank 2? Meaning the left and right cat converter? Seems the fix is the resonators, but I wanted to confirm with somebody else that this was the message they received as a result of the check engine light before taking this forum's sound advice and fixing. I've had 2 muffler shops look at it and both tell me it is the converters because that's what their machine tells them!

So basically I will have to order these parts and take them to the muffler shop and tell them what everyone said to do!
Sandra-Lia

Washington, DC

#158 Aug 10, 2009
Hey everyone -

I have a 2002 Nissan Path and two years ago I was told by a repair guy that the cats were leaking under the two front seats.

Drove to Nissan dealer in Woodbridge, VA (Cowles) smd the Service Manager told me that they were not covered as they were resonators. In order to replace the resonators I needed to replace the entire exhaust system at $1000 each. I asked him what the function of the resonator was and he said to "muffle sound". A month ago I needed to get the emissions inspected and spoke with the same manager who again told me the same story. I had the resonators cut off and the pips welded together figuring I would live with the extra noise.

Today I failed the emissions inspection because the 2002 Pathfinder has 4 convertors. Now I blew the chance to have them replaced under warranty.

It really sucks that they would have screwed me and had me pay the 2k and yet I'm screwed anyway.
Brad

Newbury Park, CA

#159 Dec 2, 2009
Thank you Nigel. I ordered Walker replacement parts from rock auto as well.
#53463 passenger side resonator
#31397 flange gasket
#31311 flange gasket
#534464 driver side resonator
#31397 flange gasket
#31311 flange gasket

Its was a little over $200 w/shipping.+~$150 for my mechanic to install. Sounds fantastic. Thank you to all!
Sparrow

Catonsville, MD

#160 Dec 9, 2009
Brad wrote:
Thank you Nigel. I ordered Walker replacement parts from rock auto as well.
#53463 passenger side resonator
#31397 flange gasket
#31311 flange gasket
#534464 driver side resonator
#31397 flange gasket
#31311 flange gasket
Its was a little over $200 w/shipping.+~$150 for my mechanic to install. Sounds fantastic. Thank you to all!
All,
first, let me state that i am not a mechanic, however i will try to be as descriptive as possible so that my comments / questions will make sence. I have a 2002 pathfinder. last month (11/11/09) I took it to the Nissan dealership for the 75,000 mile check up. after spending $750 on various issues, i drove away. two weeks later, I discovered my exhaust pipe 'dangling' loose. it had become disconnected at the pipe connection between the back muffler and the middle muffler (?). I called the dealership and complained because i felt it should have been found during the 75,000 mile check up. regardless, their estimates for repair were outrageous so I took my car to a local mechanic. the local mechanic said that i needed to replace the muffler and by the way, the CC was leaking but that it might be under warranty. My service date for the vehicle is 11/17/01. I have 78,000 miles on the car but am now 2 weeks passed the warranty limit of 8 yrs or 80,000 miles. So, I took the car back to Nissan, they said it was not the cc but the resonators that they would fix for free, due to my frustration and inconvenience. this sounded fair so i am waiting for the parts to come in. Sorry for the long story but now i get to the question: based on what i have read, it sounds like this repair kit that Nissan is going to use, will not last and the dealership knows this. it sounds like they are aware of the problems and see this as a quick fix to get rid of me. is this a fair assessment based on what I have shared?
comments? I just hate to think that the technician and the manager intentionally misled me.
Tony

Kansas City, MO

#161 Jan 16, 2010
Tim wrote:
2003 Pathfinder LE: Very noisy. Took it to Midas. They wanted $800 to replace the rear catalytic Converters on both sides. got a second opionion and he said it didn't sound like a Cat Converter at all to him but maybe a mini-muffler (whatever that is).
Finally took it to a local Muffler shop (Muffler Doctor - Kansas City). They said it was a seem on the Resonator. Replaces for $137.
Awesome!
Tim, I just bought a 2003 Pathfinder LE, unfortunately before reading this. I, too, live in Kansas City. Did you have to buy any parts? What did Muffler Doctor do? And, do you have any more problems with it? Please let me know: tonyvinh.tv@gmail.com
WhenPigsFly

Conroe, TX

#162 Jan 20, 2010
Just got the resonators replaced on our 2002 Pathfinder. Got Walker parts for $200 and it cost $120 in labor from my mechanic.

Should be good for a long time. Thanks to those who supplied the info for parts and such.
WhenPigsFly

Conroe, TX

#163 Jan 25, 2010
WhenPigsFly wrote:
Just got the resonators replaced on our 2002 Pathfinder. Got Walker parts for $200 and it cost $120 in labor from my mechanic.
Should be good for a long time. Thanks to those who supplied the info for parts and such.
Should have said "2003 Pathfinder".

Tell me when this thread is updated:

Subscribe Now Add to my Tracker

Add your comments below

Characters left: 4000

Please note by submitting this form you acknowledge that you have read the Terms of Service and the comment you are posting is in compliance with such terms. Be polite. Inappropriate posts may be removed by the moderator. Send us your feedback.

Nissan Discussions

Title Updated Last By Comments
News Automotive Minute: Redesigned 2019 Toyota Avalo... May 9 Ma Mopar 1
News California King: All-New Nissan Leaf Tested Feb '18 Solarman 1
Horn not working Feb '18 Ruben 1
News City ending contract for electric vehicle fleet Feb '18 The Liberal 2
News 2017 behind the wheel: Our favorite cars of the... Dec '17 TML_Wolf 1
News EV Range Anxiety May Be a Thing of the Past (Sep '17) Sep '17 Solarman 1
News The column where we blow up the myth that elect... (Sep '17) Sep '17 Solarman 1