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Wales
by Joske Vermeule, September 1
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Forums39
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Jun 14th, 2026
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Joined: Sep 2006
Posts: 561
OP
Talk Morgan Regular
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S4 Exhaust Bracket
Both my S4 (2008) exhaust brackets failed @ 3500 miles - picture shows fatigue fracture in the aluminium. Replacement steel brackets essential! 
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Joined: Feb 2009
Posts: 441
Learner Plates Off!
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Learner Plates Off!
Joined: Feb 2009
Posts: 441 |
Hi Orthodoc,
Can I ask how the problem presented or was it a coincidental finding?
My S4 is very close IIRC to your chassis number.
Regards,
Robert
Rbt Aero8 
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Joined: Oct 2006
Posts: 2,825
Mr Fezza Talk Morgan Expert
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Mr Fezza Talk Morgan Expert
Joined: Oct 2006
Posts: 2,825 |
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Maxxed out!
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Joined: Mar 2007
Posts: 2,321
Talk Morgan Expert
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Talk Morgan Expert
Joined: Mar 2007
Posts: 2,321 |
The std exhaust weighed a tonne! Could be partly to blame for breaking the brackets. Why not go for a sport sidepipes , much smaller and lighter, and it sound gooooood 
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Joined: May 2009
Posts: 3,727
Green & Grown Up Talk Morgan Addict
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Green & Grown Up Talk Morgan Addict
Joined: May 2009
Posts: 3,727 |
Looks like the quest for weight reduction over lightening of the bracket by cutting too much away. Then more fatigue / stress caused by the big weld so close to the narrowest part of the piece.  Only a guess but what do I know 
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Joined: Sep 2006
Posts: 561
Talk Morgan Regular
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OP
Talk Morgan Regular
Joined: Sep 2006
Posts: 561 |
Both side pipes were seen to be lower than usual and not concentric with cutouts in running board + n/s pipe very loose. When I looked at the cracked area which is lowermost in situ and moved the tail pipe - movement was clearly seen across the bracket. It was also bent if you look carefully at the picture. Also if you compare pic 1 in Ch Pramenoux series with pic 5 in Le Castellet series a difference can be seen.  The new brackets are steel which are smaller, stronger and weigh much the same!
New joints for old!
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Joined: Jun 2008
Posts: 59
Just Getting Started
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Just Getting Started
Joined: Jun 2008
Posts: 59 |
both exhaust brackets on my series 4 broke at about 2000 miles. thenreplaced broke again. i believe they replaced them with modified brackets. no problems since
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Joined: Feb 2009
Posts: 441
Learner Plates Off!
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Learner Plates Off!
Joined: Feb 2009
Posts: 441 |
Both side pipes were seen to be lower than usual and not concentric with cutouts in running board + n/s pipe very loose. When I looked at the cracked area which is lowermost in situ and moved the tail pipe - movement was clearly seen across the bracket. It was also bent if you look carefully at the picture. Also if you compare pic 1 in Ch Pramenoux series with pic 5 in Le Castellet series a difference can be seen. The new brackets are steel which are smaller, stronger and weigh much the same! Thanks orthodoc!
Rbt Aero8
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Joined: Jul 2007
Posts: 28,911 Likes: 354
Salty Sea Dog Member of the Inner Circle
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Salty Sea Dog Member of the Inner Circle
Joined: Jul 2007
Posts: 28,911 Likes: 354 |
Looks like the quest for weight reduction over lightening of the bracket by cutting too much away. Then more fatigue / stress caused by the big weld so close to the narrowest part of the piece. Only a guess but what do I know Colin Chapman syndrome??  Cheers,
Graham (G4FUJ)
Sold L44FOR 4/4 Giallo Fly
'11 MINI Countryman Cooper D All4
'90 LR 90 SW
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Joined: Feb 2009
Posts: 441
Learner Plates Off!
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Learner Plates Off!
Joined: Feb 2009
Posts: 441 |
I spoke to the factory as my chassis number isn't too far away - 667. They tell me that the very first of the S4's are fine as the wings and exhaust are located using the same bracket which are not prone to failure. Subsequent S4's changed to a separate arrangement for wings and exhaust - it's these that are troublesome. I'm hoping that I have the former as so far they remain intact! Apparently the bolt on the modified steel bracket is countersunk (as opposed to a hex bolt standing proud) which should help identify which bracket other S4's have. Hope this helps others and that your electrical gremlins are easily fixed. Regards Robert
Rbt Aero8
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