Another Exhaust Rattle Story

[PJorgen]

Last week I noticed a rattle from the rear of my "02 C4S. Definitely sounded mechanical and exhaust related. After much poking and tapping around under the car I think I've identified the source. It seems to be from the LH catalytic convertor. I'm guessing that something has broken loose inside the cat, as it rattlrs when I tap on it with a rubber mallet, and I ensured that it was not touching or rubbing against any other component.

So, as I see it I have the following options:

Do nothing. The harmonics of the rattle are such that it only rattles at idle, and it's difficult to hear in the cockpit. It doesn't seem to affect performance and I'm guessing the car will still pass smog check.

Replace it with a genuine Porsche part. Any idea of cost?

Install an aftermarket exhaust system, but I'm not sure if these systems include cats.

Comments and suggestions welcome. Is this common, anyone else have a simialr experience?

[PTEC]

This might be covered by the emissions warranty, which is 7 years or 70,000 miles. I would try calling up the dealer and giving it a shot. This problem actually isn't all that uncommon.

[demosan]

Last week I noticed a rattle from the rear of my "02 C4S. Definitely sounded mechanical and exhaust related. After much poking and tapping around under the car I think I've identified the source. It seems to be from the LH catalytic convertor. I'm guessing that something has broken loose inside the cat, as it rattlrs when I tap on it with a rubber mallet, and I ensured that it was not touching or rubbing against any other component.

So, as I see it I have the following options:

Do nothing. The harmonics of the rattle are such that it only rattles at idle, and it's difficult to hear in the cockpit. It doesn't seem to affect performance and I'm guessing the car will still pass smog check.

Replace it with a genuine Porsche part. Any idea of cost?

Install an aftermarket exhaust system, but I'm not sure if these systems include cats.

Comments and suggestions welcome. Is this common, anyone else have a simialr experience?

PTEC is correct in tha ta MY o2 should still be in warranty coverage especially here in CA. My daughter had an ACURA and the dealer replaced defective CAT with 99K miles and 9 yr old car. If I am not mistaken, CA warranty period is 10 yrs for components in the emission chain.

demosan

[PJorgen]

Great suggestion guys! I hadn't even thought about the emissions warranty, it is 7/70 in California and the car has only 40k miles on it.

Thanks!

Edited April 9, 2007 by PJorgen

[porschinator]

Hmmmm...good info people! I will check that too!

[SA321]

Hmmmm...good info people! I will check that too!

and what was it at the end? let me guess. how about broken brackets on tail pipes?

[Danyol]

Happened to me on an '02 C4S, the Cat fell apart, I thought it was a bracket too (welds break in the exhaust tail pipes)

http://www.renntech.org/forums/index.php?s...pic=544&hl=

[yizzung]

I lost two on an Audi allroad and the parts alone were on the order of $6,000. Lots of platinum in there...

[PJorgen]

Update - CEL came on about a week after I first posted. Finally got around to taking it to the dealer. Diagnosed as TWO cats performing at low efficiency, totally covered by the emission control warranty. Dealer replaced them both with no grief.

One interesting thing I learned from the service advisor; you must have a CEL for the cats to be replaced under the emission control warranty. No CEL, no warranty replacement.

Kudos to the people in the service department at Stead Porsche in Walnut Creek. My first visit there, they didn't make a dime off of me (all under warranty) and they treated me like I was thier number one customer. Excellent service experience.

[nigrellv]

Edited August 25, 2007 by nigrellv