2010 F350 ~37000miles pluged exhuast

Hi Gang.

Sorry this is long.. but wanted to have details.

I don't get here much anymore as my 2010 has been great up until this sat. Truck details. Bought it new in Jan of 2010. F350 SRW 4x4 extra cab with 8 ft. bed and V10 gas motor and 11,000 GVW. Mileage is under 37,000 Truck is used mostly for towing my toy hauler. When we 1st got it it was used a lot to haul 210 miles each way to the car track but sold all the race cars and swaped back to bikes so trips are more local except this weekend we had a double header 3 hours away. Truck felt as if a brake was dragging from the get go sat but infrared temp gun said all was fine all the tires and hubs were with in 15 degs of each other. I had pulled over twice to check thought it was just me not having hauled in a bit. Then while going up a 7 mile hill on the Mass Pike it lost all power I mean one second I'm doing 62mph the next 10mph almost got rear ended by an 18 wheeler. Had to drive 1 mile before there was a break in the guard rail to pull over. Temp climbed high and motor would not spin over 1500rpm. I could here a Whooshing noise like a popped hose or a flat tire. Pulled over and shut down the motor popped the hood noise continued for 20 seconds or so then stopped. No hoses were leaking no drips so I re-fired the motor and noted the noise coming from behind stuck my head under the passenger side and my forehead was burnt by a jet stream of HOT air out of the front steam hole in the muffler. Shut down the motor grabbed a punch and chisel and made a few quick holes re-fired the motor to allow cool water to circulate and then punched a few more holes. Drove to the rest are 3 miles away and used a drill with a uni-bit to make the holes bigger. got to the track and next day cut the case open expecting to see some of the catalytic converter in there but nothing was there. Now mind you the truck was not very noisy then I looked and saw the muffler is 3 pass type so the lower passage was still working at cutting the noise well. Anyway when I got home late Sunday I parked the truck and used a bore scope on Monday it looks as though the muffler is clear put I see there's a small unit in the tail pipe that I can't get to see what is clogging it with out cutting it out.

Anyone else had an issue like this with a gas motor? Note I do not have and never did have a check engine light. That would lead me to think the small resonator just failed and plugged itself. What says the hive?

"Smok'in the competition NOT tobacco"

2010 F350 super cab 4X4 6.8L V10 gas with 4:10 gears!

I have seen a catalytic converter break up and pile into the muffler. I can't imagine what else could do that.

I've seen 70s luxobarges with dual wall exhaust pipe have the inner wall fail/collapse and cause a massive restriction.

Methodically pressure testing along the length of the exhaust will tell you where the restriction is.

sounds very similar to when the cat broke into pieces that lodged sideways in the exhaust. very little power with a very flat powerband, could barely keep it at 70 on the highway

Depending on the warranty date you could be covered.

If it is the "cat", it is covered under the emissions warranty.

If I read this correctly, the truck pulls fine with the cat in place, and holes drilled in front of the muffler, correct? If so, its aftermarket exhaust time. Something in the muffler or tailpipe has collapsed internally. Cut it into little bits till you figure out what blocked it, then give us a picture.

probing with the bore scope leads me to believe its the smaller resonator in the tail pipe that plugged up but I need to use the truck this weekend. Dealer was called they said its out of warranty unless its the cat's an there willing and able to fix it at normal cost if its not the cats. I like how quiet the factory exhaust is....but not at the tune of $700+ for the muffler and tail pipe welded unit with hangers.

Get out the sawzall and start at the back. Stop when it blows exhaust out the proper end. Add new pipe to direct exhaust as required.

In my e30 rallycross car, in the middle of a run a couple seasons ago I lost all power. Then I braked and the engine came back to life. It would lose power upon any heavy acceleration, but was ok on light acceleration and braking.

Decided to limp it home through the small mountains. Trip started no problem, but whenever I went UP a mountain, except with the most careful of throttle, it would bog down again until I braked, it would be ok.

Fast forward to finally got home and the "brick" of substrate in the cat had broken loose (but not broken up). Every time the car accelerated or pointed "uphill" it would slide back and block the rear opening of the cat. After cutting the exhaust open I found the substrate brick still in great shape. Just not held in place any longer.

IDK if that's your problem, but it certainly sounds like something similar. Can't think of what else could physically clog a large exhaust like that.

Ya my guess is its the cats but strange thing is the muffler is a 3 pass type muffler with the lowest tube being the inlet and the upper being the tail pipe and I see no signs of any thing in the muffler and all passages seem clear to that leave the resonator in the tail pipe as the clog point. I need to check with the dealer again and see if I cut more of the system open if they will cover the cats and fix the rest with OEM parts.

Cats have a mandated 80k warranty

Talked with the dealer he said go a head and cut up the system if I found anything wrong with the cats he'd go to bat for me. I finally got around to cutting the tail pipe off and then cutting the resonator inlet open. in there lies the problem the perforated tube failed and the fiberglass packing plugged up the pipe.... pictures at. pictures

sounds like aftermarket time.

Looks like a dead rodent. Or a very small toupee.

Jerry From LA wrote: Looks like a dead rodent. Or a very small toupee.

you ran over trump and sucked his hair into your v10?