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Is the clunking/banging dependent solely on you driving over bumps or does it happen in other instances (i.e., at idle, smooth driving, cornering, etc?) Just replaced a strut mount/strut this weekend...NOT fun! The strut was so worn out that it would compress/decompress without any help but gravity. Naturally, this destroyed the strut mount. My clunking was clearly evident as coming from the front passenger side only, is this the case with yours?
As far as the front flex pipe is concerned, it is a breeze to access from the front, as others have said. Pay careful attention to the tack welds at the top and bottom of the flex itself, as these are notoriously weak. I personally had a complete separation of the bottom weld, which I think you'd notice immediately both visually and by the awful sound that straight exhaust out of the turbo makes! Even if it's only frayed, I couldn't imagine that being enough to cause the exhaust to be thrown around in that manner.
If the front flex is indeed your problem, I've read a few posts where folks have had shops successfully weld a new flex in place without having to change the whole cat-forward. Fair warning though, you'll likely have to swap the whole front pipe. It bolts up directly to the turbo and the studs on the turbo are notorious for breaking (broke two myself)...this is NOT fun unless you have a right-angle air tool to get the busted studs out or can take the turbo off for easier access. Soak the daylights out of the studs with penetrating oil before you try taking that pipe off...then say a little prayer! :)
Also, check the rubber hangers up and down the length of your entire exhaust. If one isn't seated properly or just plain broken, you might have your answer. The intermediate flex moves a bit by nature...but is shouldn't do so that much, especially if it's been recently replaced.
Finally, check your heat shield for busted/rusted out bolt holes (driver's side under the rear seat). If it's more an inconsistent rattle than a banging sound, this could be your cause. This could also explain why the rag stuck between the pipe and floorboard solved your issue temporarily.
Lots of 'ifs' here, but it can only be so many things down there and it's better than having a dishonest shop jerking you around.
posted by 75.65....
, Sat, 29 Aug 2009 09:23:44
, Sat, 29 Aug 2009 14:03:47, Sat, 29 Aug 2009 09:36:26
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