Exhaust mode selection not available.

[WItoTX]

My modes work just fine (GT350). However, about every 10th start or so, I will get in the dash "Exhaust Mode Normal", or "Exhaust Mode Sport" flashing up about every 30 seconds to 5 minutes apart. I tried chasing it down, but after I climbed under the car, I realized I probably need to do what you are doing to isolate the issue. So now I just let it flash.

I look forward to resolution on yours, as I can start the search there on mine! Good luck!

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[Atlas1]

Next update: I went to my local ford dealer and asked them to lookup the part number in the picture above. It was explained to me that this is an engineering part number and not the actual part number. Engineering part number KR3V-14B599-DA, likely translates to ford part number KR3Z-14A411-G. Considering ordering one...

Functionality update: After I reinstalled original exhaust with steeda X pipe, the problem persisted, still occasionally throwing "Exhaust mode not available" and refusing to switch out of Normal mode. Last night, on a drive to the supermarket and back, it didn't mess up once (15 min one way). My drive to the local dearlership today went the same. No mess ups. I then sat in the ford parking lot changing modes while it worked as flawlessly as the day I picked it up.

I'm at a complete and total loss as to how to proceed. The problem followed, then fixed itself???? Next nice afternoon I get, I might try going back to the Corsa and see how it goes. ffs. lol.

How good did it sound with the X and corsas?!

 

[tjwreds]

How good did it sound with the X and corsas?!

Better than stock but not by a lot. Subjectively 110% of Stock. That seems fair.

 

[Atlas1]

Better than stock but not by a lot. Subjectively 110% of Stock. That seems fair.

I imagine quite a bit louder though!

 

[silverbullet85]

instead of throwing parts at it you need to very closely look at all you wiring harness going to the active exhaust. I'm sure you have a intermittent short which would revert the valves to normal constantly and might eventually blow a fuse. If you have had a blown fuse at all on your exhaust then it is certainly a short in the wiring

 

[VictorH]

Found this, this weekend after same warning you are seeing. Passenger side.

 

[tjwreds]

Found this, this weekend after same warning you are seeing. Passenger side.

Found this, this weekend after same warning you are seeing. Passenger side.

Mine weren't exposed, but mashed a bit. They're currently working fine. If you're aren't shorting to anything they likely still work. I saw Bill from CJ Pony parts do an install with wires that looked just like that and it those still worked Check at about 5:52. Mine are for some reason, currently working properly. I don't think they're fixed yet...

 

[SloppyTX]

So, I did it. I wasn't quite happy with the mach 1 exhaust even after I put a steeda x pipe in. Put the Corsa Extreme active exhaust in.

Are there any fitment issues with the Corsa exhaust fitting on the Mach 1?

 

[tjwreds]

Are there any fitment issues with the Corsa exhaust fitting on the Mach 1?

It fits just fine, just that it seems to be the tips not wanting to work with the actuators for some reason. I still have the original exhaust back on it and it's been functioning just fine since I put it back. I'm really considering just selling the corsa at this point and moving on.

 

[Rynoe]

OP I hope you ended up finding the fix!

This old forum is still relevant sadly. My problem was adding a midpipe and lost connection 20 miles from the shop. Just for those wandering for a solution like me, attached is the Ford bulletin (Updated May 2023) and a quick fix video by Tony:

 

[MiamiGT350]

It fits just fine, just that it seems to be the tips not wanting to work with the actuators for some reason. I still have the original exhaust back on it and it's been functioning just fine since I put it back. I'm really considering just selling the corsa at this point and moving on.

My Corsa active exhaust was throwing "Exhaust mode not available" errors on start. The valves were really hard to turn by hand. Corsa then sent me a 2nd set, and they had the same problem within a few days.

Here is how I fixed all 4 mufflers: I used a trim removal tool to very gently bend the top piece (where the spring engages) upwards. The valves can now turn freely with no effort.

 

[tjwreds]

Long overdue update, sorry. I finally got new tips under warranty from Corsa. Also bought a code reader. Code reader pointed to drivers side tip error. Replaced the drivers side tip. No issues, problem solved. Everything is working as it should and sounds SO MUCH BETTER than stock.

 

[murick]

I was fixing the same problem today.
In my case I only get one wire insulation shaved (magenta one).

I did not have silicone, so I just taped green and magenta cables around and then taped all cables around to cover the exposed parts. Then zip tied them just above the tape, to prevent the tape from sliding off.

I am however not clear about what caused the wear:

1. It was just one cable in this case which was affected and kind of sideways.
2. When I attached a connector to the valve actuator there is a visible clearance between the harness and the frame (guessed at 8 mm, or 5/16")

It looks like the harness shielding would brush the frame sooner than the cable at the the connector head. In fact I have no idea what could have cut through the insulation in this setup.

Was it the connector itself? There does not seem anything close enough to do the harm...

Another hypothesis is that the exhaust pipes did get heated up (and extended) to the point the cables touched the frame. The "exhaust mode unavailable" error appeared after 2 hours of tracking.

 

[greasy]

I was fixing the same problem today.
In my case I only get one wire insulation shaved (magenta one).

I did not have silicone, so I just taped green and magenta cables around and then taped all cables around to cover the exposed parts. Then zip tied them just above the tape, to prevent the tape from sliding off.

I am however not clear about what caused the wear:

1. It was just one cable in this case which was affected and kind of sideways.
2. When I attached a connector to the valve actuator there is a visible clearance between the harness and the frame (guessed at 8 mm, or 5/16")

It looks like the harness shielding would brush the frame sooner than the cable at the the connector head. In fact I have no idea what could have cut through the insulation in this setup.

Was it the connector itself? There does not seem anything close enough to do the harm...

Another hypothesis is that the exhaust pipes did get heated up (and extended) to the point the cables touched the frame. The "exhaust mode unavailable" error appeared after 2 hours of tracking.

The exhaust definitely expands when hot and your cold clearance diminishes.

What caused mine was a didn’t trim enough of my exhaust when putting on my x-pipe. To fix I trimmed about 3/8” more off of the stock exhaust, I depinned the harness, cleaned up the mangled wires, double heat shrinked the wires individually, the reassembled. Mine were much worse than yours.

You running an aftermarket mid pipe? You might want to trim where you cut from again or at a bare minimum move the exhaust as far forward as possible otherwise you will face this issue again.

 

[murick]

The exhaust definitely expands when hot and your cold clearance diminishes.

What caused mine was a didn’t trim enough of my exhaust when putting on my x-pipe. To fix I trimmed about 3/8” more off of the stock exhaust, I depinned the harness, cleaned up the mangled wires, double heat shrinked the wires individually, the reassembled. Mine were much worse than yours.

You running an aftermarket mid pipe? You might want to trim where you cut from again or at a bare minimum move the exhaust as far forward as possible otherwise you will face this issue again.

I have a stock exhaust. What might have happened is, I had some Steeda parts mounted by someone else, including the diff. bushings. It is possible that the guy when reassembling the pipes did not push them together enough and left a smaller clearance at the end.

I hope it might be easy to check, though I am not sure how hard it could be to slide the pipes in (I assume he might have had a reason).

I have read the TSB posted above, and checked the pipe seating. The exhaust clamps are not locked, but the converters seems to be as tight as it gets, while clamps look rather short. For what concerns the muffler connection, I am not sure I have any "ridge" on the pipe, looked smooth more like GT500 pic (in the TSB). Whether they are inserted for proper length I have no idea.

I guess I will have to look into it again. Unfortunately I can only do it in a public shop, so probably next weekend.

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