Exhaust Leak From Front Catalytic Converter on Mercedes-Benz ML320

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: 123,738 (54,545–200,000)
6 model years affected: 1998, 1999, 2000, 2001, more2002, 2003
32 people reported this problem
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problem details
2000 Mercedes-Benz ML320 54,545 mi,
loud noise when starting vehicle, sounds like a cheap motorcycle! Calling dealership today for an appointment.
2000 Mercedes-Benz ML320 55,000 mi,
Catalytic converter was replaced. Paid for by dealer, even though I was out of warranty. (apparently it was a known issue)
2001 Mercedes-Benz ML320 120,000 mi,
Small crack on top of cat. Some exhaust leakage, but very minor. Did not affect operation, did not repair.
2002 Mercedes-Benz ML320 150,000 mi,
Not covered under recall, have not yet fixed problem. Thinking of welding.
2000 Mercedes-Benz ML320 146,000 mi,
Crack in weld catalytic converter drivers side, just replaced passenger side converter was clogged, $1100 2 months ago. Did not want to spend another $1100 so quick. Mercedes is an expensive car to maintain, I liked my Jaguar better. If it wasn't for the wife this car would be gone. $150 for oil changes, $300 fix dash lights, bad gas mileage.
2001 Mercedes-Benz ML320 159,000 mi,
Rattle noise took it to exhaust shop fixed it by doing some welding not sure if it's still need service or replacing mercedes should recall this issue !!!
It want pass smog due to vacum line.
1998 Mercedes-Benz ML320 172,000 mi,
Check engine light came on and car stalled out. Had it towed to garage and had a cracked catalytic coverter! $1500 paid to install new one! Should Mercedes hav covered this?
2000 Mercedes-Benz ML320 84,949 mi,
notice a noise getting louder. took it in to Mercedes dealership, 2 hairline cracks. one on each side. have not got repaired yet.
1999 Mercedes-Benz ML320 166,000 mi,
Driving on highway doing 80 mph when the engine light comes on and the car slows to 40 mph. Went to a local service station and was told that the real convertor cracked. Both back convertors now need to be repaired at a price of $430 each plus labor.
2002 Mercedes-Benz ML320 165,000 mi,
all catalytic converters failed, without know reason or problem. regular scheduled maintenance performed on vehicle
2000 Mercedes-Benz ML320 128,800 mi,
put put sound under car, passed emissions, took to Meta Motors for diagnosis, did not fix, sold car
2000 Mercedes-Benz ML320 69,000 mi,
The passenger catalyctic converter is leaking and starting to leak in the driver's side giving a weird noise.
2001 Mercedes-Benz ML320 83,000 mi,
center panel covering bubbles and is coming off.
Couldn't afford to replace it. Did weld it. Now car w/143,000 miles on it and check engine light due to emissions!