Porschedane

996 3004 Rattle in muffler. On my 996 the left muffler is sometimes rattling and I was wondering if it would be a good idea to open it up and fix the rattle? Has anyone done it and can it be done?

Chiamac

The baffles go out - mine rattles a lot - and sure it could be fixed or mitigated if they are opened up. I think it's just a matter of welding the baffle in place, or doing something to tighten it down.

Do a search for a thread about gutting the mufflers, it has some pics that will help as well as a google image search for what's inside.

Gonzo911

Mine used to rattle, but it was the pipe clamp and not the actual muffler.

5CHN3LL

It can be done - another RL member had one of my rattly Tubi mufflers opened up to fix a loose baffle. However, a rattle from that area is often not the muffler - a loose heat shield rattling against the muffler seem to be the most common culprit.

Seeeu911

^966

RickMiller

+1 - that's what my rattle turned out to be. 5 minutes of massaging the heat shield and all is good.

Porschedane

Thanks for suggestions I will have a look over the weekend.

JTT

My rattle turned out to be a cracked stud for the exhaust tips.

Porschedane

Hi JTT on the cylinder head?

JTT

No, the tailpipe tips. There is a little stud welded to the tailpipe that holds stainless tips.

Porschedane

Thanks I will look there.

Porschedane

After much thought I decided to remove the left muffler cut it open and see where the rattle came from. And sure enough the inside baffle had come loose, just a little bit but enough to make a loud irritating noise. I welded the parts together inside the muffler then welded back the double layer outside cover that I had cut away with angle grinder. Now it sounds just like a new again we shall see how long it will last.

alpine003

Glad you were able to salvage it. Loose baffles are usually the case in internal rattles. For anyone else that may have this issue in the future, you don't necessarily need to cut the case open. I recommend drilling through both case layers at the key areas where the baffles rests(raised areas) and you should be able to spot weld it. Pic of the two baffles below.

Porschedane

It may work for some and perhaps worth the try but I cut mine open and also welded the 2 connector pipes since they seemed loose also and in glad I did.