Pse Rattle

[Mann]

I have a 2004 996 C2 with PSE and 35k miles. This passed winter the car started developing slight rattling exhaust noise when driven cold, somewhere between 1k to 2k rpms. The rattle would go away after the car got to a normal operating temperature. It has gotten a lot worse since the winter. Now it sounds a lot louder and as if something is knocking inside the muffler metal to metal. It takes longer to go away and even when it's hot you can still hear noises as if something is loose inside the muffler and it just rambles around. The noise is coming from the driver side only. Switching PSE on and off does not affect the rattle. Since my car is certified I took it to Porsche of Rockville for diagnostics. These geniuses recommended replacing exhaust tips and conveniently quoted me 800 for the job. The recommendation didn't make much sense, so I took the tip off to test it and sure enough the noise is still there. Has anyone experienced that? What else can I do to isolate the problem?

Thanks for your insight.

Edited May 17, 2010 by Mann

[GoBruins]

If I had to guess, I'd pick the elements in the cats are going bad.

[JamesD]

I had the same problem in my C4 about a year ago, same symptoms.

There is a few fix's.

1.Check your heat shields that there not in contact with anything that could cause the noise and all the exhaust brackets, make sure none have come lose.

2.If your sure it's the muffler! you can cut it open and weld the lose piece of metal. (but this fix can cause more problems, so I would not unless your a real good welder)

2.If it's the cat the only solution is to change the cat.

3.Change your whole exhaust system for a new one (this is what I did)

So really I think when it comes to exhaust rattles the only real solution is to change for a new one (after verifying that it is either a brokeing muffler or cat)

You cloud try and get a second hand one at a junk yard, but then that one cloud have problems too?

I got a nice aftermarket one, but I think (not sure) you can get other aftermarkets exhausts that will work with the PSE button on the dash?

James

[Mann]

Right, I took it to an indie shop today and they immediately told me I need a new muffler. The cost of driver side alone for just the muffler is around $2,600. Looking at aftermarket options now.