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My RS2 has developed a rattle at around 4000 revs which apears to be due to the catalyst breaking up. I belive the cats (approx £500 each and there are 2) are specific to the model.

Anyone had a similar problem? I now show 102,000 miles and the MOT emissions test result was well within limits only last month.

Will it still pass if the cats inner is burned out, or replaced with a straight pipe section?

Thanks for any help you can offer,

Stephen

My ABY-engined S2 has done 130k miles and mine are fine. I haven't heard of this happening before. I think that the cats in the RS2 use a ceramic carrier for the catalyst material and I can understand this being brittle especially after several years of thermal cycling. Your cats haven't taken a whack from a speed bump or something have they? Since they are down either side of the gearbox they are potentially prone to damage.

Since you might soon choose to embark on a CAT replacement excercise why not save some money and get Milltek high flow cats fitted. Highly recommended exhaust system fabricators. When I change my turbo I will proceed to get them fitted to mine to go with the Milltek 3" system I have already fitted.

Alternatively, if it really ain't broke, don't fix it. If performance isn't affected and you fail the next MOT on emissions replace it then.

Haven't heard of a common problem with these. Mine has 152 000 km, and no worries with cats.

I'm under the impression that RS2 cats are metallic, and thus high flow. If one is indeed broken, you might want to consider some other high flow metallic cat if these are cheaper.

Jani
RS2 -95 MTM380+