Awful Exhaust Noise
Awful Exhaust Noise
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XM5ER

Original Poster:

5,094 posts

278 months

Monday 11th February 2013
quotequote all
Advice please chaps.

Was making progress along the mway yesterday when the exhaust suddenly went very, very loud. I looked in the mirror expecting to see bits of metal bouncing down the road but thankfully not. I slowed down to a reasonable speed and it went quiet again and stayed quiet. When returning home later it did the same thing, again, only at high speed. Now it seems noisier at tick over and in general sounds a bit farty. The office sage recons I have a broken baffle (he did used to have a 997 so he does know a bit about them), is this a regular thing? Or am I just unlucky.

Any thoughts?

Gibbo205

3,572 posts

237 months

Monday 11th February 2013
quotequote all
On my PSE one of the internal baffles went, a local exhaust fabricator opened it up, welded the baffle back and all was fine again. smile

XM5ER

Original Poster:

5,094 posts

278 months

Monday 11th February 2013
quotequote all
Gibbo205 said:
On my PSE one of the internal baffles went, a local exhaust fabricator opened it up, welded the baffle back and all was fine again. smile
When it went, is that how it sounded?

Does anyone know of a fabricator that could do that in the NW?

gtphile

191 posts

195 months

Monday 11th February 2013
quotequote all
It could be the exhaust manifold to cat flange fixings corroded, causing a blow between them.

It is fairly common on the 996.

If you can, look under the car, you will see the manifolds come out from under the heads, follow it to a flange with 3 studs/nuts on it, check for a gap there.

It would be around an hours labour, and about £25 in parts to sort.

XM5ER

Original Poster:

5,094 posts

278 months

Monday 11th February 2013
quotequote all
gtphile said:
It would be around an hours labour, and about £25 in parts to sort.
I prefer the sound of this smile

It does sound quite plausible as all the heat sheilds were replaced last year also due to corrosion.

Gibbo205

3,572 posts

237 months

Monday 11th February 2013
quotequote all
XM5ER said:
When it went, is that how it sounded?

Does anyone know of a fabricator that could do that in the NW?
Mine sounds like beans in a can all the time, bloody awful noise.

Take it to a garage they should be able to identify what part of the exhaust has gone, whatever it is should be easily fixable.

As to a good place, JP Exhaust in Macclesfield are excellent. smile

RiccardoG

1,758 posts

302 months

Monday 11th February 2013
quotequote all
gtphile said:
It could be the exhaust manifold to cat flange fixings corroded, causing a blow between them.

It is fairly common on the 996.

If you can, look under the car, you will see the manifolds come out from under the heads, follow it to a flange with 3 studs/nuts on it, check for a gap there.

It would be around an hours labour, and about £25 in parts to sort.
This happened on my 997 (at around 50k miles). It sounded like it was farting.

Leaning under the car you could see the issue clearly. Cost 25 to repair!

gtphile

191 posts

195 months

Monday 11th February 2013
quotequote all
On a 996, you need to heat up and press out the studs, and replace with nuts and bolts, plus cost of a new gasket, so you did well to find someone to do it for £25! The gaskets are £7 a pair, plus nice new stainless nuts bolts and washers.

It can actually take longer than an hour, but that is a reasonable time to charge.

RiccardoG

1,758 posts

302 months

Monday 11th February 2013
quotequote all
gtphile said:
On a 996, you need to heat up and press out the studs, and replace with nuts and bolts, plus cost of a new gasket, so you did well to find someone to do it for £25! The gaskets are £7 a pair, plus nice new stainless nuts bolts and washers.

It can actually take longer than an hour, but that is a reasonable time to charge.
They just refastened the loose clamp. Six months later its still holding up (touch wood!!).

Martian O

2,734 posts

192 months

Monday 11th February 2013
quotequote all
XM5ER said:
...Does anyone know of a fabricator that could do that in the NW?
http://www.sportsandclassic.com/

XM5ER

Original Poster:

5,094 posts

278 months

Monday 11th February 2013
quotequote all
Gibbo205 said:
JP Exhaust in Macclesfield are excellent. smile
Thanks.

If we get a dry spell today (highly unlikely) I will get under the car and have a nosey. If I can't see anything obvious I will pop down there one lunchtime this week. Ta!

Actually, now I come to think of it, I have heard a bit of a metallic clunking sound coming from the back end of the car in the last week. I had assumed it was something suspension related (I dont know why) and was planning for a service shortly.

XM5ER

Original Poster:

5,094 posts

278 months

Monday 11th February 2013
quotequote all
Just nad a look and we appear to have a culprit. The exhaust manifold to cat flange fixings are indeed corroded to buggery. Started it up and could feel the blow through on both banks of cylinders, the way all the bolts under there are corroded is actually quite appalling, I had no idea that Porsche were buying Fiat bolts these days.

gtphile

191 posts

195 months

Monday 11th February 2013
quotequote all
RiccardoG said:
They just refastened the loose clamp. Six months later its still holding up (touch wood!!).
Different fault! You are talking about the sleeve that joins the cats to the exhaust silencers I think!