Rattle-free at last!

Just got the Cayman back from the dealer's shop, where they spent the last eleven days looking for the source of a rattle I'd had since I got the car 16 months ago... The rattle sounded like it was coming from just behind the driver's seat, around the rear quarter window. Since the window "floats" in the frame rather than being bonded in place, I suspected window movement was causing the rattle. It would "click" when changing gears or over uneven road surfaces. It seemed like it was related to torquing of the body. Turns out it was the airbox, where it attaches to the body. (The rotational movement of the engine during gear shifting, etc, was making the noise.) They lubed the connection point, tightened it, and all's well. Of course, they'd completely stripped out the interior panels on that side of the car trying to find the source, so there was a fair bit of reassembly required. So... I know other CC members are hearing rattles from behind the driver's left ear... now you know one more place to check to try to solve the problem. My car is sooooo much more enjoyable to drive now that the rattle is gone! :banana:

Thanks! I've had some similar rattling, thinking it was the dreaded trunk-clunk. But this is more likely.

I think I have that same rattle coming from the passenger side, do you think it is safe to assume that the cause is the same? To me it sounds like a chirp.

Congrats on getting it solved, hopefully this problem is isolated to only a few people as I doubt something like that would be common, but at least now people know it is something to check for.

I have had that same damn rattle. I have tried to fix it myself, and had the dealer take two cracks at it! I am taking it back in for the trunk clunk, so I am tempted to have them check this out also. However, I have desnorked the car...is this something they will notice? TIA

Someone who knows better might chime in here, but I think the airbox only attaches to the car on the left side. So if your rattle/ chirp is from the right side it's likely to be something else. You can do a search to see posts relating to rattles from the seatbelt anchor bolt area, the quarter window, the hatch, etc... any of which might be helpful.

I think they accessed the problem area from the inside... i.e by removing the engine cover and checking for noises coming from down in the area of the airbox intake. They may not notice your desnork but I wouldn't count on it. They may even say the desnork caused the rattle and make you pay for the repair rather than do it under warranty. Can you put it back to stock before taking it in?

Yes, I could put it stock if I had too. I think Im going to attempt this fix myself today. I hate taking the car to the dealer because I just dont trust them, however, I believe in using the warranty too...so we will see. I also have to take my car in next week for the TSB on the trunk clunk...if I have not fixed the problem by then, I will have the dealer look into it. If this fixes that rattle, you are my hero!! BTW. I have tightened down that rear quarter window a few times now. The first time I did it, the noise was noticeably less, just not completely gone. Im hoping that the last little bit of noise is coming from the airbox!

I wish I'd been in the shop to see this fix while everything was apart... for future reference. I know what the window assembly looks like (from K-Man S's excellent articles and photos), but I don't know how the airbox attachment point works. If you attempt this fix yourself, some pictures might be in order... then you can be the hero for those who follow! Have fun!

I am starting now...and will document my process!

ok, so I basically followed two articles. I removed the engine lid and I took out the air cleaner...all things that can be found in the article section. I noticed once I cleaned and put the air filter back into the box, it had a tendency to wobble and rattle when it hit up against the left side of the airbox/body. I placed a little piece of foam on the outside of the filter and then put it back into the box. Now the filter is held in place very firmly and does not make a rattle sound anymore. Im going for a test drive...results to follow.

Added some padding to the air box and....NO rattle! Thanks for getting me going on this.

No problem! :cheers:

I had the exact same problem and became frustrated that even after three visits to the dealer, they continued to ignore my suggestions that the problem was in the engine compartment not with the trim. I based this diagnosis on the fact that it rattled more when the engine was under load (and therefore canted over more) than when coasting with the clutch depressed. I took the engine cover off myself, ran my hand round the back of the airbox, and levered it away from the bodywork ever so slightly, no more than a millimeter or so. That was about four months ago, and I've had no problem since. 10 minute job at the most. Marco.