Join Date: Apr 2002
Location: Dandridge (Near Knoxville), TN, USA
Re: Exhaust Rattle
Exhaust pipe stubs broken where they go into the head is a not uncommon occurrence. Several of us have had this, and they can be welded. On mine, the front two were broken.
Loosen the exhaust stud nuts on all four cylinders, and see if you can rotate the flanges any at all. Any that are broken will allow the flange to rotate a little due to the clearance between the studs and the holes in the flanges.
The welds between the end of the pipe and the flange breaks, allowing the pipe to rattle even though the nuts are tight.
Another not uncommon problem is the weld between the catalytic converter and muffler sections cracking, but this is an exhaust leak problem, and does not rattle.
There have also been cases of the exhaust support breaking. That is the part that is bolted to the center stand support plate, and is connected to the muffler by a loop of heavy spring wire. The wire loop sometimes breaks, and can cause a rattle.
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