waynesworld

I have been dealing with a very annoying rattle from the passenger's side muffler on my 2000 C2. These mufflers have an inlet tube, a crossover tube, and an outlet tube that work together with the three chambers to muffle the exhaust. I used a plasma cutter to open an access panel in the outboard side of the can and found most of the welds had fatigued and failed. The crossover tube was loose and causing the rattle. I used a mig to re-weld the tubes and then a tig to reseal the access panel. Attached are a few pictures for reference in case others run into a similar problem.

-Wayne

Barn996

Very clever, nice fix, good pics.

befast

I probably have the same exact issue! However, I took the approach of acquiring 3.6l cans.

UCrazyKid

I'm thinking about attempting this to fixing a rattling PSE muffler

Robin 993DX

The factory 996 mufflers are very poorly constructed.

DCNSX

How has your repair held up? Looks like a nice job but I don't have those tools.

I have the same problem on my '00 C2 as well (driver's side). I am buying one used muffler from eBay for $90+40 shipping = $130. The "donor" muffler has 52k miles on it. Junkyards are quoting $175-185 shipped for one muffler, FYI.

Robin 993DX

Cheaper to just buy a ebay muffler and throw it away when it breaks and buy another one.

waynesworld

The repair has held up well. Any exhaust shop should be able to do the repair for reasonable cost.

-Wayne

Edgy01

Excellent writeup. This is probably more common a problem than we realize.

pierre_l

I am about to do the same on my mk2 with pse mufflers and was wondering if anyone had pictures of similar jobs done on mk2 - even pse! to make sure I don't cut the wrong place.
thanks,
pierre