Exhaust Leak From Front Catalytic Converter on Mercedes-Benz ML430

An exhaust leak may develop due to cracked welds on the front catalytic converter. Replacement of the catalyst is recommended; re-welding of the catalyst is discouraged because it is an emissions device.

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Average mileage: 99,666 (73,000–145,000)
3 model years affected: 1999, 2000, 2001
7 people reported this problem
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Viewing 1 - 4 of 4 problem details
2001 Mercedes-Benz ML430 145,000 mi,
Catalytic converter has a crack at the joint where it is welded. this is a design flaw from the manufacturer
crack in front catalytic converter. going to replace. oh joy. Amazingly, the car was running better than we can remember in a long time, right before it happened.
cat is bunk and torsion bar is in the way when removing. Crap weld!
Cat cracked and had it welded, told by Mercedes mechanic it is a huge design flaw, one of many.