Exhaust Rattle Passenger Side / 997 S Cabriolet USA

[mwswenson]

2006 997 S Cab 16,000 miles. Six speed with sport suspension, sport exhaust, short shifter etc.

Exhaust rattle from right (passenger) side of car at idle and low RPM - sounds exactly like a loose heat shield. Mechanic and I inspected car on hoist; heat shield not loose and no apparent defects in muffler. As a test, we inserted a pry bar into the tail pipe, lifted up and the rattling sound went away.

As a short term fix, we inserted a bolt between the muffler pipe and cat effectively raising the muffler about 3/8 of an inch but rattling noise returned but not as bad.

Also, right muffler is the one that is activated by the sport suspension to create a deeper tone - we removed the switch inside the engine bay but that made no difference - rattle was still apparent.

My thinking is it the bracket that attaches to the muffler which in turn is mounted to the body.

Thoughts and thank you in advance!

[Booboy]

I have an '07 S experiencing the same issue. I too thought sound is resonating from the muffler, but now not sure. Will try the same tensioning with pry bar and see what gives...any others experiencing this issue?

[Loren]

I would check in this order: loose or bent heat shield, bad muffler, bad catalytic converter. 

[Orient Express]

This sort of rattle is usually a catalytic converter that has the internal honeycomb cracked or broken.  If the car is less than 7 years old or 75K miles Porsche will replace it under warranty. 

[wvicary]

Friend has a 2005 Cab and something came loose inside the muffler and caused a rattle- had to replace the muffler.

[Booboy]

Checked with Porsche about warranty for CAT, my warranty expired in January this year. Asked if they could help as problem was identified prior to warranty expiration, and was investigating issue... and they said, "NO, but maybe the dealer can help you, if you have a good relationship with your dealer sometimes they may help you out".

Don't understand why Porsche can't help me, but the dealer might? Unfortunately all my Porsche purchase's (7) to date have all been through private owners.

Had a 2000 Ford pickup bought new that lost a motor out of warranty and Ford replaced it FREE. Frustrating!