Bad Muffler “SOUND” 2010 3.5l

[Rgant_1981]

I have a 2010 Journey 3.5 R/T with 155777 miles on the dash. After replacing the upper manifold with a used one from the junk yard (which is going on 3 wks now). It’s not sounding the same it did when I had the original manifold installed with the engine codes p0660 & p01005. I sounds like it needs a new muffler because you can hear me passing by. Remember, no codes on dashboard. Now the code p0401 did pop up but went away. I know the erg valve can make it run rough but with no codes, it seems odd. You would think it will throw an exhaust code or something… It feels like it’s pulling hard when I give it gas while driving. Anyone can tell me what it could be…? 

[John/Horace]

It's an egr code. So sticking unit and possibly bad gasket on the egr adding to the noise. Flow runners in the old intake manifold were often bad for creating codes.

[Rgant_1981]

That’s the thing, it’s no code… I even took it to the emissions testing site yesterday and passed with the loud sound. The guy took off my gas cap and hooked up the detector. Also hooked up to my OBD connector and it passed. Even though I scanned it on my own before, I was sure he was going to find something but he didn’t… I was thinking it could be the EGR but no code. So I’m puzzled 🤔!

[5rebel9]

For a code to show up the actual plunger of the egr valve has to malfunction. This does NOT rule out the pipe having a hole in it that goes from the EGR valve to the exhaust manifold....and probably the cause of "loud muffler" sound.

Edited December 28, 2024 by 5rebel9