Strange rattling sound from APR exhaust?

[egalley]

Hey guys,

I've noticed a strange rattling sound coming from the drivers side muffler. I really notice it on cold start-ups and low speed driving like going through a drive-thru. It's like something is loose in there.
Any one else experience something similar?

Thanks,

[Chestlock]

I believe NWS4Guy mentioned in a recent thread that he had something come loose in one of his cans. Shoot him a PM, and let APR know. They'll take care of you.

[CreoSTi]

On acceleration, I sometimes notice what sounds to be a rattling noise (like something in the exhaust shifting). It doesn't happen all the time, and usually only once the car is warmed.

[Arin@APR]

You'll want to get the car on a lift and see if a heat shield has fallen or something else is rattling. If the sound is actually coming from the exhaust, we can warranty any defective parts.

[jjslegacy]

Mine seems to have a flat sound almost like something is loose rattling at low speeds. I don't drive the car all that much so I don't remember it always doing that. I'll have to check it out

[egalley]

You'll want to get the car on a lift and see if a heat shield has fallen or something else is rattling. If the sound is actually coming from the exhaust, we can warranty any defective parts.

Thanks Arin!
I'll get it up on a hoist asap. I does sound like something has come lose in the muffler, like a weld or something. I'll speak with our APR distributor to get it checked out.

Thanks,

[egalley]

3 months later and APR still hasn't replaced my exhaust under warranty. Things were moving along great when it was just dealing with APR in the States. They sent up a replacement but it turned out to be for an A4 not an S4. So that went back through my local APR dealer. Now APR decided to create APR Canada out of Calgary. Why Calgary, I have no idea! Now it's just a sh*t show. My APR dealer here in Ottawa has been awesome and wants this to get replaced. I don't know why we need to go though APR Canada. Calgary needs specific part #'s now. My local dealer needs come over now and get under the car for parts numbers. Can't they just call APR in the states? This is going to delay things another week since I have to go out of town for work.
If I had the time off It would have been easier to drive down from Ottawa to Opelika AL. Ugh!

[AofC_RR]

3 months later and APR still hasn't replaced my exhaust under warranty. Things were moving along great when it was just dealing with APR in the States. They sent up a replacement but it turned out to be for an A4 not an S4. So that went back through my local APR dealer. Now APR decided to create APR Canada out of Calgary. Why Calgary, I have no idea! Now it's just a sh*t show. My APR dealer here in Ottawa has been awesome and wants this to get replaced. I don't know why we need to go though APR Canada. Calgary needs specific part #'s now. My local dealer needs come over now and get under the car for parts numbers. Can't they just call APR in the states? This is going to delay things another week since I have to go out of town for work.
If I had the time off It would have been easier to drive down from Ottawa to Opelika AL. Ugh!

I feel you. I've got a customer we installed an APR exhaust on their B8 S4. We've been waiting for 40+ days for a replacement mid-muffler/resonator.

[egalley]

Oh! I thought it was delayed just cause of APR Canada. You're in the states! Wow!

Bummer.

[NWS4Guy]

Email or PM Evan or Arin, they should be able to get you both a status.

[CBRmatt600]

I've had my APR exhaust adjusted 3 times now because the mufflers will make contact with the car over certain speedbumps and other less than stellar road surfaces. I think the last adjustment got it to the point where it will not bang around under most normal driving, but every once in a while it will still bang against the underside of the car over certain bumps. I've just learned to deal with it, I assume most other aftermarket systems will do the same and the sound this thing makes more than compensates for the minor inconvenience.

[///mpowered]

3 months later and APR still hasn't replaced my exhaust under warranty. Things were moving along great when it was just dealing with APR in the States. They sent up a replacement but it turned out to be for an A4 not an S4. So that went back through my local APR dealer. Now APR decided to create APR Canada out of Calgary. Why Calgary, I have no idea! Now it's just a sh*t show. My APR dealer here in Ottawa has been awesome and wants this to get replaced. I don't know why we need to go though APR Canada. Calgary needs specific part #'s now. My local dealer needs come over now and get under the car for parts numbers. Can't they just call APR in the states? This is going to delay things another week since I have to go out of town for work.
If I had the time off It would have been easier to drive down from Ottawa to Opelika AL. Ugh!

OMG I'd be so pissed!!! Hope you get this sorted out asap! I feel you on the "APR Canada" issue!!!!

[NWS4Guy]

Muffler shouldn't rattle or make any contact, if the shop know what they are doing, and has muffler jacks to properly position the setup before tightening it down it's not that hard to do.

[Arin@APR]

This is completely unacceptable!

Both of you, egalley & AofC_RR email me your name, customer information, dealer you're working with, contact at APR you're working with, and if you happen to have the list of emails sent back and forth, send those too. I'll make sure this gets to the right person and gets sorted.

Email address: [email protected]

I'm out of the office today, but I should be able to get it to the correct parties to be sorted. out.

Thank you

-Arin

[81bear]

I've had my APR exhaust adjusted 3 times now because the mufflers will make contact with the car over certain speedbumps and other less than stellar road surfaces. I think the last adjustment got it to the point where it will not bang around under most normal driving, but every once in a while it will still bang against the underside of the car over certain bumps. I've just learned to deal with it, I assume most other aftermarket systems will do the same and the sound this thing makes more than compensates for the minor inconvenience.

My exhaust doesn't move at all. Slight vibration and very deep tone on cold starts but zero issues with it moving or banging on bumps.

[81bear]

OP - The guys at APR (US at least) have always been great with me, I'm sure they will sort this out for you!

[Deep Sea S4]

I agree, nothing but great service from APR USA. I know not of this Canadian office of which you speak

[NWS4Guy]

Same here with my replacement, which is why I said days ago to do what Arin just asked you to - email him.

[Evan@APR]

Oh! I thought it was delayed just cause of APR Canada. You're in the states! Wow!

Bummer.

Yes, any delay has nothing to do with APR Canada. Being that your name isn't visible on the forum if you could PM me your information I'd be happy to get you updates. Thank you!

[egalley]

Yes, any delay has nothing to do with APR Canada. Being that your name isn't visible on the forum if you could PM me your information I'd be happy to get you updates. Thank you!

Evan,

My intent is never to bash APR. I've spent way too much money on your great products over the years.
I'm just a bit frustrated how the process for my local dealer has changed, and is being delayed even further.
I have emailed Arin as as he requested. He has my info.

[PCHS4]

My APR exhaust resonator failed after 15,000 miles - makes a loud rattling noise like something in loose inside. The APR dealer has been very helpful and contacted APR to replace the resonator, but things are moving very slowly over at APR. It's great to have a lifetime warranty, but I hope the part gets replaced in my lifetime. lol.

[Hsiang]

Wondering if the Lifetime warranty only works on the original owner?

My APR exhaust resonator failed after 15,000 miles - makes a loud rattling noise like something in loose inside. The APR dealer has been very helpful and contacted APR to replace the resonator, but things are moving very slowly over at APR. It's great to have a lifetime warranty, but I hope the part gets replaced in my lifetime. lol.

[PCHS4]

I would guess it is only for the original owner, which I am. I had a previous experience with APR when the exhaust was first installed and it took 8 months to resolve. I have been happy with the exhaust, just not very happy with their customer service.

[PCHS4]

I wanted to post a follow up to acknowledge and thank Ian at APR for resolving the issue and sending out new parts. With the help of Mason at GoodSpeed in Scottsdale, AZ and David at EuroCode in Torrance, CA. Parts were sent out to EuroCode and they did the install at no cost and as usual the customer service there was awesome.

[Chestlock]

Wondering if the Lifetime warranty only works on the original owner?

Nope - the warranty follows the exhaust if you sell the car so I've been told by APR.

[saxon]

Nope - the warranty follows the exhaust if you sell the car so I've been told by APR.

this is not correct, they put the blame on corsa and say that corsa only warranties it for the original owner (which would be understandable if these exhausts were 10 years old)

here is the issue and how i had mine fixed, its actually very easy and the welder said he wouldnt be surpsised if this happened to all of the cars that have it.

again , this is a very easy fix and hopefully apr/corsa has figured it out and the new mufflers dont have this problem

Untitled by saxonbrian2, on Flickr

Untitled by saxonbrian2, on Flickr

the pipe that goes through the muffler isnt actually welded to the outside (the rear of the muffler) and eventually it comes loose
Untitled by saxonbrian2, on Flickr

a couple new welds
Untitled by saxonbrian2, on Flickr

Untitled by saxonbrian2, on Flickr

Untitled by saxonbrian2, on Flickr

Untitled by saxonbrian2, on Flickr

[PCHS4]

How much did all that work cost?

[KRracer]

Interesting internal glimpse. Is the tube just slipped into the can exit? You say it's not welded.

Also, I can't tell, but did your welding guy forget to put the packing material back in? There is some laying around the muffler in each photo, including the one that is being welded back up.

Cheers,

KR

[NWS4Guy]

Great pics thanks for sharing! Yes the first few of these I was told had the issue and it was fixed on a subsequent revision. I've had both my rears replaced, though the other one took 4 years to rattle.

Interesting internal glimpse. Is the tube just slipped into the can exit? You say it's not welded.

Also, I can't tell, but did your welding guy forget to put the packing material back in? There is some laying around the muffler in each photo, including the one that is being welded back up.

Cheers,

KR

There IS no packing material, that is how RSC works, it uses the frequencies of sound that are unappealing and drone, to cancel themselves out based on the size of the RSC channel, no packing needed, and it's a straight through free flowing exhaust.

[saxon]

How much did all that work cost?

He said he would do these for $100 + shipping. Apr quoted $500 for a replacement muffler

Shoot him an email, his name is Jason
[email protected]

[infinkc]

this is not correct, they put the blame on corsa and say that corsa only warranties it for the original owner (which would be understandable if these exhausts were 10 years old)

here is the issue and how i had mine fixed, its actually very easy and the welder said he wouldnt be surpsised if this happened to all of the cars that have it.

again , this is a very easy fix and hopefully apr/corsa has figured it out and the new mufflers dont have this problem

Untitled by saxonbrian2, on Flickr

Untitled by saxonbrian2, on Flickr

the pipe that goes through the muffler isnt actually welded to the outside (the rear of the muffler) and eventually it comes loose
Untitled by saxonbrian2, on Flickr

a couple new welds
Untitled by saxonbrian2, on Flickr

Untitled by saxonbrian2, on Flickr

Untitled by saxonbrian2, on Flickr

Untitled by saxonbrian2, on Flickr

Mine is doing the same thing, I contacted apr and since I was not the original owner I am out of luck, they quoted me way higher than 500 for the muffler. Sux cause it was bought with the car not bought off another member, you would think warranty would transfer. The one on my car was replaced also by the previous owner, was about 1 year old and it failed again. Pretty crappy design if you tell me. Looks like I will be cutting mine open now and doing what you did.


For 2500 you would think you would get better quality and service.

[saxon]

Mine is doing the same thing, I contacted apr and since I was not the original owner I am out of luck, they quoted me way higher than 500 for the muffler. Sux cause it was bought with the car not bought off another member, you would think warranty would transfer. The one on my car was replaced also by the previous owner, was about 1 year old and it failed again. Pretty crappy design if you tell me. Looks like I will be cutting mine open now and doing what you did.


For 2500 you would think you would get better quality and service.

Send an email to my friend, great work and cheap imo

[PCHS4]

My resonator on the APR exhaust failed (rattling inside) pretty early on and APR did replace it. I am running the Milltek resonated for about 1 year now and no issues. Having seen both up close my impression is that the Milltek build quality is much better.

[meth0d68]

....all I see is the words APR and Fail in this post....yikes. I may just stay with my stock exhaust.

[will13k7]

....all I see is the words APR and Fail in this post....yikes. I may just stay with my stock exhaust.

mine's holding up well, one of the newer builds (2013). sun roof open under a highway overpass and some throttle and high rpms is awesome! because racecar of course!

[saxon]

....all I see is the words APR and Fail in this post....yikes. I may just stay with my stock exhaust.

I wouldn't say that...

I know awe had problems with resonator failure. Apr will absolutely take care of you if you buy it New, I bought mine or owned so therefore no warranty

[drob23]

the pipe that goes through the muffler isnt actually welded to the outside (the rear of the muffler) and eventually it comes loose
Untitled by saxonbrian2, on Flickr

Good job on the pics, so what exactly do those remnants around the pipe on the muffler consist of? It looks like something was done to hold this in place? Why is there that bead? Maybe the inner tube is heating up with the exhaust gas, and destroying whatever connection was made?

[egalley]

mine's holding up well, one of the newer builds (2013). sun roof open under a highway overpass and some throttle and high rpms is awesome! because racecar of course!

I do that too. Haven't had any issues with the new version as well.

[saxon]

Good job on the pics, so what exactly do those remnants around the pipe on the muffler consist of? It looks like something was done to hold this in place? Why is there that bead? Maybe the inner tube is heating up with the exhaust gas, and destroying whatever connection was made?

The back of the welds that you see are what holds the "y" pipe on the rear of the muffler. I'd imagine those welds were supposed to hit the inner pipe but didn't

[966SS]

I do that too. Haven't had any issues with the new version as well.

Rattle just started with mine, had it for 2 1/2 yrs. Initial reaction from the crowd in Calgary not encouraging.