garrett1021

So after my father and I had enough of this horrendous rattle we decide to jump under the jacked up car with a rubber mallet and go crazy. The cat. The cat was ringing and buzzing when hit, after a few hours and bloody hands galore we finally got the heat shield removed. It was 11pm but we were insanely happy. We started up the car and

VHJFSRTJNJJHBVRRSTIOBGUBSEYJOBFSTNONFTFETJIJFEYJJBFEYNN

Yup the rattle was still there, there was a slight high pitch ring that was gone though.

Today we removed the RIGHT rear wheel and searched and searched with that mallet. No luck.

He had given up and was searching solutions in the internet when I had crawled under the car. Thats when..... that's when I saw this. On the muffler.

abarthguy

Well, that would do it !

garrett1021

You don't even want to know how many hours were spent trying to locate that horrible sound. It was right in front of us the whole time...

garrett1021

Also can anyone tell me if I can just get a pipe that completely bypasses that whole muffler? Is that what a G pipe is? Im thinking about getting my local muffler guy to just fab me up a small pipe and completely get rid of that muffler

Mr.Alex

Yes, the G pipe bypasses the secondary muffler (the one by the rear passenger wheel). Theres a few places to get it, but I'd post in the For Sale thread here to see if any member is looking to get rid of his. Or just fabricate one.

garrett1021

Thanks for the clear answer!

N24

I may have had a similar problem on my previous 964 (in 1993!) - I'd fitted a Ruf bypass pipe instead of the left-right rear silencer - a few months later the secondary silencer split & needed to be re-welded.

I've been since told that removing the rear silencer causes the secondary to overheat and then split, then if left unchecked can cause problems melting the wires that side of the engine. So on my current 964 I still have the rear silencer, and a G-pipe instead of primary bypass.

All I need now is to have it back from the three garages it was last seen in...

C24FUN

I had a similar problem with my secondary muffler. I suspect it was the result of driving in a wet climate with some road salt exposure by the PO. Some patient searching on eBay eventually turned up a near new replacement for $50!

Since then I have been running stock CAT and secondary only (primary removed), a period of about 10 years. There has been no further sign of corrosion or splitting on the replacement so I'm not sure about the "overheating" theory. Mine is a summer driver only so has very limited exposure to rain.

Cheers!

Jim G.

AB-Oz

I had same problem, I believe it is caused by a hot spot created by a cup pipe, which a PO used in replacement of the primary muffler.

I fitted a G-pipe but it was far too loud combined with the cup pipe, I ended up selling the g-pipe and getting a second hand secondary muffler off ebay.

D.C.

I have a G-Pipe for sale if you wanted to go that route.

Send me a PM if you are interested.

Dave
in Fairfax Va.

hawk911

I have a nice condition secondary

velocitylover

This is a common problem on cars with primary bypass (I went thru 3 of them - the last one: Dansk sport muffler was the strongest but it cracked as well). Eventually I welded the last one for a spare and moved on to B&B headers and their muffler - problem solved
I'm not sure if it's the heat or resonance of exhaust flow that "blows" them out like that... maybe some Rennlist experts can chime in?
Btw: I do have a pretty "lead foot" so I'm sure this speed this up in this department

garrett1021

PM'd

RW964

Hey Garrett get the G pipe I have one but its the long ver maybe called a J pipe with a chip and I am told a lot that my 964 is one of the best sounding cars.. You will like it .. Well I do anyhow ..

garrett1021

louder=better

any videos of the sound??