JPS3290

02 STi (UK) with 31k miles.

I had been to the lakes wed/thurs with no noise when arrivng home. From the following day i heard a metallic rattling noise when starting the car up as it was echoing off the wall in the yard. Once on the road i couldn't hear it.

Now after another 50ish miles i can hear it when driving through villages at 25-30mph. Searched on here and it seemed the heat shields could be the culprit as its seems to virbrate with the engine speed.

Ive checked them all today and tightened them all up (not that they were really loose) and its still there. With it off the ground i think it seems to be coming from the bottom of the down pipe just were it starts to head along the bottom of the car? Sorry, not very technical but there seems to be quite a few resonator or cat box/silencers i have no idea which is the cat or silencer box. It really does sound very err how can i put it, high pitch rattle like theres nails or glass in the pipe.
My guess is it could be a knackered Cat if that bit of pipe is the cat?? Its the bit that comes from the turbo and goes down over, noise seems to come from the bottom near the bend.

Car seems to be driving as normal. Would an engine warning light not come on if the cat was on its way out? Although its 3 yrs old its only odne 31k! Also not sure if ive been driving it harder or not lately but it does seem to be drinking slightly more lately, or is that the warmer weather?

Help lol I hate rattly noises!

JPS3290

No one? lol

Had another look and decided its not the cat. The heat shield behind the turbo? area downpipe is causing it but how the hell do you stop it?

Ive tighened all the bolts up with no success. When i take two of the bolt out near the bottom (easiest ones to get at) and start the car up the rattle goes completely, but then comes back when engines up to temp. If i put them back it when cold its there from the start.

Im tempted to get the warranty renewed (was going to shortly) and just get the dealer to sort it as im sick of it

RON

What can happen is that the shields crack around the bolt, so even tightening it does sod all, try putting a washer under the bolt, one thats bigger than the bolt head..... you never know!

JPS3290

Ive shone a torch down and the shields look fine but i'll give anything a shot!

I actually had tried to put a washer behind the shield to lift if off the area its bolted to slightly but its impossible to get both hands down to keep the washer in place and bolt through it lol.

I'l try what you say tomorrow and see what happens.

Thanks mate!

Markyboy uk

I had a very similar noise when I changed my DP on an MY01 Bugeye. The cause in my case was the bolt that secures the DP to the transmission bracket area was not tight enough. Tightened it up, no more rattle

Worth a check.

JPS3290

Well had the I/C off today to have a good look down the back and nothing seemed loose. Took it to a SUbaru specialist which happens to be in my village and at first the guy thought it sounded like the turbo bearings were starting to collapse and ground/catch.

After spending a good 20-30 mins without charge it looks like it might be the release bearings in the clutch. The rattle is not there when cold or very hard to hear but after 1/2 mile or so it gets louder. With the car parked up he held the revs at 2-3k and the rattle was awful but when pressing the clutch in the noise goes.

So any experts think it does seem like the release bearing?
Cant believe after 31k its gone. Only done 1.5k of them myself and personally know the previous owner didnt drive the car as intended. I do know it was a dealer demo so maybe thats worn the clutch prematurely or is 30k average????

I've had a price off him for a new clutch kit (might as well do the lot while its out) and seems fairly expensive. £476 + VAT all in fitted. Thoughts on cost would be appreciated. Im tempted to get an uprated clutch but cheapest i can find on the net is £407, that with 7.6hrs labour is gonna be extortionate lol

RON

476 +vat is a good price if that includes fitting, getting the gearbox out and back in can be a real pain...... i've done mine twice in three weeks..... and when the box falls on you it flippin hurts!!

never worth doing it yourself if that price includes the fitting...

Ron.

JPS3290

Yeah including VAT it will be about £560. He said that they use to remove the engine which took about the same time but he's bought some kind of new hoist/lift/frame thingy that when they take the gearbox out takes all the weight and allows it to be manouvered safely and easily. No idea personally as although ive worked on cars (engine rebuilds etc) i've never touched a gearbox. Apparently its not much quick removing the box but saves the hassle of remove coolant etc.

Looks like i'll just go ahead and say order the parts if thats a good price. Thanks for replying mate.

RON

At least he won't have the box falling on him then eh!!!

JPS3290

Dropped car off this morning at 9am. Still no phone call yet, hope everythings going ok. I asked if they had time to fit my front brakes pads for me but think i was pushing it Sure they shut at 5 so hoping im not without a car tomorrow!! argh

McWRX

I have this similar type noise that I can only relate to pinking or tappets at 2k RPM in 3rd and 4th only...

If I drive at these revs in 1st or 2nd its not there?! Strangley if i pull into my garaged area (walls either side) i can sometimes hear a faint rattle when i release the clutch.

However if i rev it while stationary and the clutch is out i cant hear the noise. Only when driving... and when i put the engine under load in 3rd or 4th...

Is this the same as yours?

MY51 Bugeye WRX...

JPS3290

My noise could be heard with the car idle or being revved. Couldnt hear it much over 3.5k due to normal engine noise probably drowning it out. Sometimes when driven a few miles it would go then come back but was there 90% of the time.

It sounded like a heat sheild which does seem a common problem with them but had them checked and wasn't them. A garage checked it over last week and thought it sounded like the clutch release bearing because as the engine was revved even in neutral the noise just got louder not faster (like it would if it was the turbo on the way out). Also when pressing the clutch in the noise either went completely or just about stopped.

Yesterday it was awful to drive, seems to suddenly of got worse and biting at the end of its travel and has always been really hard to press which i took as normal for an STI. Also very hard to change gear smoothly and 1st/2nd gear hard to engage yesterday.

Just had a call 15mins ago from garage who confirmed new clutch is fit and release bearing was worn. New clutch apparently feels much easier and smoother to press. They asked to keep car overnight to do some checks on it and also fit my front pads so have let them keep it.

I'll let you know tomorrow what it drives like.

Hope that helps. How many miles has yours done?

McWRX

Great thanks,

Mine has 32k on it now, but started this about 1k ago and before I had the middle decat fitted. My exhaust was rotted so i assumed it was to do with this. And part of it was. Maybe it is just a heat sheild now... would they make a noise if I was stationary and had the clutch out revving? The engine sounds fine if i have it engaged in gear, out of gear, clutch in, clutch out while stationary but 3rd and 4th just make the slight noise at the below revs.

Strangely enough, it was very cold last night and the noise really didnt show up, and I was trying hard to get it to reproduce. Seems to be a tad louder on hot days.

I can literally only relate mine to a tappety noise between 1800RPMS and 2000RPMS.

Hope the new clutch gets yours sorted!

Have mine booked in at a garage to get them to double check it... will pop the results up.

JPS3290

Well picked the car up and its great. Clutch is so much easier and smoother to press than before its amazing. Release bearing was worn and the splines? were stiffer than they should be as though they had started to seize. 3 hot spots on the clutch plate itself and it was down to the rivets so was practically out of material.

Only done a couple of mile in it but seems great. Now got to bed my EBC red ceramic pads it which alrady feel better than the knackered standard pads!