825i Exhaust pipe issue

[missouri gator]

A few months back my machine started getting alot louder than usual, I thought the muffler had burned out. When I started checking it out I noticed the leak was coming from the pipe that goes into the muffler. I called the dealer and they came and got it, the next day they called and said the exhaust pipe had broken where it comes out of the motor and they would order a new one. The following day I had my gator back.
The problem is they have replaced that same pipe 3 times now and the one on it now is broke again. Has anyone else been having this problem? My dealer said since I found this problem on mine about every one they have in for service they check them and more than half of them are broken.
Deere is telling them that they think it is a heat issue but they have not came up with a solution yet. Some of the Deere Techs that are on here please chime in if you have been experiencing anything like this.
Mark

[RMOSSSO1]

Logic tells me that I would check for engine alignment first. After that, perhaps you, JD, should check for a loose motor mount. Seems unreal that you experienced this many problems. For it to break, something is not aligned or not capable of expansion/contraction with heat. I will look at my machine tomorrow for the pipe coming out of the engine. Keep us updated on what happens.
Thanks,
Rich

[missouri gator]

Rich, I agree with all you said, myself and the dealer has checked and compared mine to a new 825 and we cant seem to find any difference. The strange thing is this exhaust pipe doesnt mount solid, on the engine end where it connects to the manifold its held on with two springs the only other carrier is the rubber mount in front of the left rear tire and then it slides into the muffler which has no clamp.
I was expecting that other forum members might be having the same issue but that must not be the case. I just talked to the dealer and he has replaced over 2 dozen of these pipes, so if you think your gator is louder than usual have it checked out.

[RMOSSSO1]

Mark, aka M. Gator:
I raised the bed on my machine, VIN ...LAM013769; Engine s/n ...GAF01152. These are the suffix numbers, I eliminated listing the prefix letters/numbers for obvious reasons. Perhaps you can use this info with your dealer, as I have nothing like you describe above.

I have a manifold, then bolted with two bolts, hard fastened, to the exhaust pipe. About 15 inches from the engine is a pyrometer into the exhaust. Then the exhaust continues with two elbows. I did not take off the aluminum foil which appears to cover a joint of the pipes.

Perhaps someone with knowledge can check why there are two different designs. Unless I am blind and deaf, I have no cracks or breaks as of this time and date. Probably less than 250 miles and less than 100 hours. Only a couple hard bumps and no wrecks or sudden stops. I am the only driver and am very careful.

Hopefully this info might help resolving your problem. Let me know if I can provide more info. I didn't have time today to take photographs as I have company coming to my home tomorrow, but let me know if photographs will help, and I will provide.

Good luck with resolution,
Rich

[jasonwaldner]

We've got 2. 825i gators with the same broken exhaust. Welded it brakes again
Dos anyone have a solution on how to fix my problem. Or r there any updates.
Please let me know thanks. JJW

[Zephyr74]

Can anybody upload a picture of their broke exhuast pipe?

Thanks.

[dale5387]

I have 1800 miles now. There seems to be more exhaust coming out of the joint where the muffler and the exhaust hook together under the foil wrap then what is coming out of the muffler. Does anyone have any thoughts or suggestions??

.

[missouri gator]

Since I started this post I have had my exhaust pipe replaced 8 times the last time being this morning, all I can get out of JD is that they are working on it. The dealer has a stack of old broken pipes must be at least 25 or more, they dont even send them back to JD anymore. If anyone has a # for JD customer service other than what is in the book I would like to have it, something has to be done to correct this problem, I urge everyone to call JD about this issue and maybe as a group we can get something done!
Thanks, Mark

[dale5387]

I took the foil cover off used muffler cement, sealed that seam, wrapped it with muffler tape ( very heavy aluminium foil) that did the job.

[CentMO3088]

I had the same thing as missourigator is describing, of course my dealer had never heard of it and didn't seem to excited about even looking at it. Told me to bring it down and leave it and they'd try to get to it in a couple of weeks. It appears to me that the pipe has the wrong bend to it at the engine end and that causes it to be too short for the joint at the muffler to seat completely. I took a 2x4 and did a little careful prying at the bend and that allowed the joint to go together. I haven't had any trouble or didn't see any evidence of anything broke.

Bottom line I was very disappointed in my dealer as this was the first issue I had since taking delivery nearly a year ago. Mine had been loud from the start but I just thought thats the way all of them were.

I'm curious to know who missourigator deals with. I won't mention my dealers name yet because my grandma told me not to say anything if you can't say something nice.

Mike

[AUSaltfish]

Same issue here. I recently ordered the Stealth Exhaust and was very excited to see how much improvement I would see - nothing different which lead me to look harder. I thought this Gator (2012 825i) was oddly loud. After taking off the heat shield I saw, herd and felt the exhaust coming out of this junction where the muffler pipe connects to the exhaust pipe from the motor. From the posts above it appears JD has no answer and I am not interested paying for service if the same issue will occur again putting me back to square 1 to replace again at another service charge. I am going to try the exhaust cement and tape approach myself as described above and if there isn't vast improvement with fixing the obvious leak and the putting the silencer back on - selling this thing as its way too loud for hunting purposes - even embarrassed to ride it in the neighborhood do to the loudness of the exhaust. If anyone else has any advice please let me know as it appears this is a common issue most don't even know about as they just assume the gator is supposed to be that loud.

[missouri gator]

I had the same thing as missourigator is describing, of course my dealer had never heard of it and didn't seem to excited about even looking at it. Told me to bring it down and leave it and they'd try to get to it in a couple of weeks. It appears to me that the pipe has the wrong bend to it at the engine end and that causes it to be too short for the joint at the muffler to seat completely. I took a 2x4 and did a little careful prying at the bend and that allowed the joint to go together. I haven't had any trouble or didn't see any evidence of anything broke.

Bottom line I was very disappointed in my dealer as this was the first issue I had since taking delivery nearly a year ago. Mine had been loud from the start but I just thought thats the way all of them were.

I'm curious to know who missourigator deals with. I won't mention my dealers name yet because my grandma told me not to say anything if you can't say something nice.

Mike

Mike, The dealer is Deems Farm Equip. Marshall MO They have recently sold and changed name to Ag Power. It sounds like you have had yours apart I bet if you take those 2 springs off that holds the pipe on and remove the pipe and look at it you will see its broken and thats what changes the bend in it. If you have a small mirror you can examine the pipe without taking it off. As I stated in an earlier post today I have purchased another UTV just because of the noise. I will contact my JD dealer next week on any updates.

Mark

[AUSaltfish]

Just did the same and a vast improvement especially with the silencer. Only one issue, after a loop aroudn the neightborhood the muffler/tailpipe cement is smoking pretty bad. I am going to let it sit and see if it possibly just wasnt completely set up but I gave it more time than stated and put a heat gun on it so not sure if this stuff is going to hold up. Also could have just been the adhesive backing cooking off the tailpipe tape. Well see but thanks for the input!
I took the foil cover off used muffler cement, sealed that seam, wrapped it with muffler tape ( very heavy aluminium foil) that did the job.

[CentMO3088]

Thanks for the info Mark. I have bought a used farm tractor and a grasshopper mower from Deems. Real good people, just too far away from my place. I bought this gator a little closer to home but it's the only thing I have ever purchased from this Deere dealer, probably will be my last too. I'll have to look at my pipe a little closer when I get time. I had it off when I was "tweaking" on it to make the joint close up and didn't notice anything.

Mike

[missouri gator]

OK guys just talked to my dealer, JD has came out with a new exhaust pipe that is supposed to fix the problem. The part# AM144601 is the new pipe be sure they install this # and not one of the original ones that they may have in stock. I hope this takes care of some of the exhaust noise.

[LeonardS]

OK guys just talked to my dealer, JD has came out with a new exhaust pipe that is supposed to fix the problem. The part# AM144601 is the new pipe be sure they install this # and not one of the original ones that they may have in stock. I hope this takes care of some of the exhaust noise.

Will John Deere cover it as a product update or do we have to pay for the new exhaust?

[CaptDan]

and what Gators are affected ?


Dan

[dieselsmith]

:lurk:

[missouri gator]

My 825 is a 2011 and there has never been any charge to me, I do have the extended warr. I dont know if this is considered an update or not or exactly what years are affected. A friend of mine has a 2012 and he has had his replaced twice at another dealer at no charge. If you can hear exhaust noise in front of the muffler I would have your dealer check it out. JD is aware of the problem so dont let them BS you about not knowing anything about it!
If GATORDONE reads this post he may be able to add some info.

Mark

[emnesto]

Does anyone know when the new exhaust pipe started being used in production? Other then opening the foil cover and looking for a leak, is there any way for me to tell if I have the new exhaust pipe?

[GATORDONE]

We have had a few that we replaced including mine, The pipe change was made some time in may or june, Only thing I can tell you is that it is a tighter fit and different sealing rings were they join together. If your gator is out of warranty I would suggest having the dealer contact there service rep for possible help paying for the new pipe, As of now it is not a product improvement or recall.

[flu_byu]

I just replaced mine aswell for the 3rd time , I have a deluxe cab on my gator , and here is what I did to fix the issue , I installed fox shocks because my rear tires bottomed out , therefore it was touching the muffler and pushing it forwards, and I changed all my motor mounts , and they were worn out and that caused the motor to torque sideways way over its limits under load , causing the muffler to crack right at the springs, I got 15000k on mine and 4912, and its still running fine

[Cjmi0927]

Hi guys I'm new to the form I have a 2013 mines has been changed out twice already and is going on the third time as it is broken again. I think what is going on is the motor is moving from torque and the pipe will move with the motor but the muffler is bolted solid so the pipe is bottoming out in the muffler and bending the pipe at the 90 witch causes the seal where the two springs are to leak. That's what I think is going on. Just my two cents.

[Cjmi0927]

Lol sorry I have a 2012 not 2013 I have about 1250 miles and 143 hours on mine.

[campoman]

unfortunately the sleeve gasket or ring whatever you call it isn't replaceable I am having a new pipe built at a friends muffler shop and a quiet muffler installed , I could let you know how this works out, if your interested , im with you the gator is way to loud for hunting , im hoping this works out other then that I really like this machine I have done a few modifications to improve it for one , the air cleaner was in aboit the worst spot for dust so I fabricated a snorkel to get it up in clean air flow this has worked incredible don't seem to be buying air cleaners as before lasts three times as long and recently went to a k n so now just rinse it off contact me if your interested in these mods 619 4051635

[fastgun]

From reading this and other posts I checked my loud buzz machine 825i. My pipe was broken in the bend where the pipe attaches to the header.
Replaced it with the latest part number and it is not as loud. Still a small leak at the header side bend, but the sleeve gasket or ring side has zero leak.
If this pipe (which is the 3rd product update from John Deere) breaks, I think I would get a custom made pipe also.

​Please do post how your project works out.

[campoman]

I am having the same issue , I find out this exhaust pipe has been upgraded twice any one solved this problem ? im considering taking Gator to muffler shop and having a whole new pipe built for this and maybe even a quieter muffler, Its just to noisey even when it was new to hunt with.

[campoman]

has john deere decided this exhaust issue on the 825 to be a recall issue yet and compensate us for it , they don't seem to be to worried about it , I am very disappointed in the response on this seems like they would be more concerned about their customers satisfaction , I really like my 825 , but I think parts prices are way out of line , and they wont let us access computer info with a obd2 code reader ,they have made info un accessible unless you take it to the dealer these code readers and the snap on scanner read every vehical on the road from 95 and up except john deere what is with this , they want all the acces to themselves if I hadn't of already bought my 825 I believe I would of bought a can am, seem to have much better customer relations then deere, o well maybe dere will start being more concerned about there customers in the future but probably not very likely, I paid 17000. for this machine and I cant access my computer for info , something not right there.

[campoman]

From what ive found out the dealer wont cover this problem , they don't seem to be to concerned about loosing customers ive talked to numerous people with this issue and the new replacement pipe dosent address the problem , most owners have decided to sell the Gator and go to a different UTV Can Am or Ranger, I like my 825 except for this issue that deere should be correcting,, but no luck I am going to fabricate a flange like used on header collectors so the exhaust pipe and muffler pipe can be bolted together with a bell connection on the pipe I will let you know how this works , maybe JOhn Deere will pay me for fixing there problem but I doubt it

[campoman]

what year is your Gator my 2018 has 2 bolts holding pipe to manifold

[campoman]

there are two different systems I believe they changed from the spring mount to the bolt system on the exhaust manifold about 20 13 I have a 2014 , it has the bolt on systemhave not had any leaks there had a leak at the connection where the exhaust pipe slides into the muffler pipe I used high temp silicone and seems to be working the main exhaust noise is coming from the muffler all that is needed to diagnose where there is a leak is a rag over the tail pipe outlet you can hear exactly where any exhaust noise is coming from, hope this helps . I am looking for a muffler that can be fabricated to fit in the original housing that would, solve the loud exhaust,and that popping noise that is so irritating.

[campoman]

I would thik the real fix for thes spring mount exhaust would be change the exhaust manifold to the bolt on exhaust pipe which I believe was changed in about 2013 , but I find the popping noise and loud exhaust is the muffler , Im trying to find a muffler that will take the place of the stock muffler , this would be the real fix to quiet these down , hope this helps

[Dyno Dan]

Well, after dealing with the exhaust leak for some time I did some research. Ended up buying the AM146297 pipe and it’s certainly different, it’s longer and a different angle on manifold side of the equation.

Also the muffler was full of water and something was loose inside it. I cut it open, found the “well seasoned catalyst” floating around, and the fiberglass packing that’s between the outer shell and internal chamber of the muffler was saturated in water / condensation.

Removed the catalyst piece by piece and then welded back up. Also a drilled two 3/32 holes in the bottom to allow the muffler to piss off the condensation.

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