Rattling from the front

[softail]

I have a very annoying rattle from the front of the car, which seems to be on the nearside. It's been in to the dealer twice now, the first time they lubricated the exhaust mounting rubbers,(which didn't solve the problem) and the second time they cable tied the valves on the rear box of my non-res. Miltek, claiming they were rattling but the problem is still there. I've been underneath the car and I can't see where the rattle is coming from as the exhaust seems to be clear of the body throughout its length and the valves don't rattle, but the noise is there when I go over small holes in the road. I don't think its the DRC as the noise is a rattle rather than a thump and the front dampers were changed about 2k ago. The dealer has fully inspected the front suspension and says there is nothing wrong with it and the handling seems to be ok. The other thing I've noticed is that the noise is a lot worse when the car is cold and eases off a bit after about an hour but it's still there. Has anybody had any similar issues with their Milteks. I'm convinced it's not the exhast but the only way forward would be to put the old system back and see if it persists. Any ideas before I spend another £50 swapping the exhaust?

[Nib]

The last time I had something similar (not in the RS4 I should add, and not with a Miltek), it turned out to be a loose cell/baffle in the cat or silencer (can't remember which).

Hope you track it down soon. Things like that can really take the shine off using the car!

[JonRS4]

On my resonated Miltek setup, I had what could be called a rattle although I think a creak would be more accurate as noise descriptions go.

It was caused by the front frame cross member coming in contact with the exhaust. At rest, it looked like there was clearance (paper thin) but with heat, it expanded and rubbed on the pipe. I installed the system myself so a simply twist and I was away to the races. I did end up taking off the cross member to diagnose the problem and recall you need an 8mm triple square bit. It was frustrating because when cool, no issue. With the cross member off, you could see the rub, so to speak.

[softail]

On my resonated Miltek setup, I had what could be called a rattle although I think a creak would be more accurate as noise descriptions go.

It was caused by the front frame cross member coming in contact with the exhaust. At rest, it looked like there was clearance (paper thin) but with heat, it expanded and rubbed on the pipe. I installed the system myself so a simply twist and I was away to the races. I did end up taking off the cross member to diagnose the problem and recall you need an 8mm triple square bit. It was frustrating because when cool, no issue. With the cross member off, you could see the rub, so to speak.

Jon - Thanks for the info but I had a look under the car at the weekend and I couldn't see a cross member. Where about is it, my exhaust just runs down the centre of the car and is supported on rubbers in the middle and at the rear boxes.When I took off the old exhaust from the Cat, I wasn't obstructed by a crossmember. Any help would be appreciated.