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MK1 Muffler Rattle - Internal Repair

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10 captured repliesDiscussion pagination complete · Source accounts, not a confirmed diagnosis
THIS DISCUSSION / SOURCE-DERIVED OVERVIEW

Discussion summary

YOUR RESEARCHMK1 Muffler Rattle - Internal Repair

Leading reported evidence

Use mig

Performed · outcome unconfirmed

No successful repair reported for this finding.

0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context

Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.

Discussions that performed work without a confirmed outcome
1

0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.

0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.

Performed · outcome unconfirmed · Original poster

I used a mig to re-weld the tubes and then a tig to reseal the access panel.

Original post Read captured discussion
MK1 Muffler Rattle - Internal Repair
Frequently discussed work

Repair has held up well

No successful repair reported for this finding.

0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that contain suggestions
1

0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.

0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.

Suggestion · Original poster

The repair has held up well.

Original post Read captured discussion
MK1 Muffler Rattle - Internal Repair
Read full discussion summary

Leading evidence: 'Use mig' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Repair has held up well' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.

Source reports, not a diagnosis or a success probability. Counts refer to discussions and can overlap.

Read captured replies

1 matching discussions · 10 captured posts examined · 0 partial discussions

Compare 4 other evidence results

Use muffler

Performed · outcome unconfirmed

No successful repair reported for this finding.

0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context

Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.

Discussions that performed work without a confirmed outcome
1

0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.

0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.

Performed · outcome unconfirmed

I am buying one used muffler from eBay for $90+40 shipping = $130.

Original post Read captured discussion
MK1 Muffler Rattle - Internal Repair

Use plasma cutter

Performed · outcome unconfirmed

No successful repair reported for this finding.

0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context

Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.

Discussions that performed work without a confirmed outcome
1

0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.

0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.

Performed · outcome unconfirmed · Original poster

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.

Original post Read captured discussion
MK1 Muffler Rattle - Internal Repair

Repair has held up well

Suggestion or failed attempt

No successful repair reported for this finding.

0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context

Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.

Discussions that contain suggestions
1

0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.

0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.

Suggestion · Original poster

The repair has held up well.

Original post Read captured discussion
MK1 Muffler Rattle - Internal Repair

Repair held up

Suggestion or failed attempt

No successful repair reported for this finding.

0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context

Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.

Discussions that contain suggestions
1

0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.

0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.

Suggestion

How has your repair held up?

Original post Read captured discussion
MK1 Muffler Rattle - Internal Repair
Frequently discussed actions (8)

These are separate views of the same evidence. Frequency alone does not establish a fix, and these counts must not be added together.

Repair has held up well

No successful repair reported for this finding.

0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that contain suggestions
1

0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.

0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.

Suggestion · Original poster

The repair has held up well.

Original post Read captured discussion
MK1 Muffler Rattle - Internal Repair

Repair held up

No successful repair reported for this finding.

0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that contain suggestions
1

0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.

0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.

Suggestion

How has your repair held up?

Original post Read captured discussion
MK1 Muffler Rattle - Internal Repair

Repair reasonable cost

No successful repair reported for this finding.

0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that contain suggestions
1

0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.

0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.

Suggestion · Original poster

Any exhaust shop should be able to do the repair for reasonable cost.

Original post Read captured discussion
MK1 Muffler Rattle - Internal Repair

Reseal access panel

No successful repair reported for this finding.

0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that contain suggestions
1

0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.

0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.

Suggestion · Original poster

I used a mig to re-weld the tubes and then a tig to reseal the access panel.

Original post Read captured discussion
MK1 Muffler Rattle - Internal Repair

Run into a similar problem

No successful repair reported for this finding.

0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that contain suggestions
1

0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.

0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.

Suggestion · Original poster

Attached are a few pictures for reference in case others run into a similar problem.

Original post Read captured discussion
MK1 Muffler Rattle - Internal Repair

Use mig

No successful repair reported for this finding.

0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that performed work without a confirmed outcome
1

0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.

0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.

Performed · outcome unconfirmed · Original poster

I used a mig to re-weld the tubes and then a tig to reseal the access panel.

Original post Read captured discussion
MK1 Muffler Rattle - Internal Repair

Use muffler

No successful repair reported for this finding.

0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that performed work without a confirmed outcome
1

0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.

0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.

Performed · outcome unconfirmed

I am buying one used muffler from eBay for $90+40 shipping = $130.

Original post Read captured discussion
MK1 Muffler Rattle - Internal Repair

Use plasma cutter

No successful repair reported for this finding.

0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that performed work without a confirmed outcome
1

0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.

0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.

Performed · outcome unconfirmed · Original poster

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.

Original post Read captured discussion
MK1 Muffler Rattle - Internal Repair
Coverage and how to read this overview

Counts describe captured discussions, not unique people or a diagnosis. Author identities are not reliably stored. Exact duplicate evidence is counted once across matching discussions; one discussion counts at most once per action/state. Multiple repairs reported together remain a combination. Suggestions and failed attempts do not establish a fix. Matches cover whole discussions and can include related faults, model variants and incomplete threads.

10 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.

  • Rennlist: 1 discussions

0 evidence records excluded for query context · 0 excluded by outcome qualification · 0 adjusted by outcome qualification.

0 acknowledgements have no verified action link; they do not establish a repair result.

Generation: 20261026T144035Z · outcome-qualification-6. Deterministic extraction; no AI model inference. How we use sources

POST 1 / ORIGINAL POSTEROriginal post

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

POST 3Original post

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

POST 4Original post

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

POST 5Original post

The factory 996 mufflers are very poorly constructed.

POST 6Original post

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.

POST 7Original post

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

POST 8 / ORIGINAL POSTEROriginal post

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

POST 9Original post

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

POST 10Original post

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

This is a source reference. Confirm exact model applicability in the original material.