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STILL HAVE A "RATTLE"
#1

As some of you may be aware, I had an engine bay "rattle" develop after driving my 93 coupe (after the purchase) from North Carolina to Chicago. With 90K miles on the car, and the rattle sounding sort of like a loose timing chain, I decided to tackle an upper end inspection of the cam sprockets and replacement of the varicam chain and pads. This was a 12 hour job that took me close to 6 weeks to complete, since my wrenching time is very scarce these days! At any rate, the cam sprockets looked fine.....no broken teeth or teeth overly thinned out....so, I went ahead and changed out the cam chain and pads and "while I was in there", I also did a front end reseal and replaced all the rollers and belts.



She fired up on the first try, and other than a slight whine from a slightly too tight balance shaft belt, she seemed "better". I took her for a drive and the performance was good and unchanged, but when I returned to my garage.....there was the "rattle" again. No different or worse than when I decided to do the cam chain. Since it is almost impossible to tell where the rattle is coming from, I am going to pick up a stethoscope from Sears and give things a listen.



My question for the 968 Forum.....is where could the rattle be coming from if not from the cam chain? It kind of sounds as though it might be coming from the clutch area, but at this time, that is only a guess. Any ideas or direction that any of you can provide would be greatly appreciated.



What in the area around the clutch would cause a rattle? The noise is loud enough that you can just hear it when inside the car. It does not sound like lifter clatter. And, it is noticeable from standing in front of the car or to the side of the car. When I get the stethoscope, I plan on putting the car up in the air and probing different areas. I believe that the flywheel is original as is the pressure plate. The dealer indicated that he had just replaced the clutch disc and was reluctant to replace the entire clutch assembly.



What should I be looking for?
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#2

A rattle that I noticed shortly after I purchased my car was very hard to pinpoint. It sounded metallic, and so had me worried. Upon further inspection, I was relieved to find out it was the exhaust manifold heat shield. Have you tried applying pressure to various parts/shields while the car is running (carefully of course)?



Good luck, and I hope it's nothing too serious. At 90K, it wouldn't be too bad if it were the clutch.
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#3

earossi: bad throwout bearing can cause rattle up front...but you can tell because it usually becomes less noisy when you step on the clutch pedal. usually it is louder when hot. I would have expected this to be replaced with the clutch disc..check receipt.
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#4

Thanks for the replies. I hadn't thought about heat sheilding. I'll take a look tonight to see if I can figure out what sheild you are talking about. If it is the heat sheild, what would have changed to have it come in contact with something that would make it rattle? Engine mounts? Loose attachment bolts?



On the idea that it might be the throwout bearing, I'll try to see if the noise changes with clutch engage/disengage or with engine speed. I have experienced throwout bearings go bad on past cars, but the symptom I am used to hearing is more of a bearing whine than a rattle. Is a rattling T.O. bearing something unique to these 968's?
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#5

I didn't read the whole post but something to check is the heat sheild around the header. Mine has a small crack near the front mount that lets it rattle at times, very hard to see (no chance to touch it with out removing the header)
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#6

[quote name='968rz' post='52823' date='May 19 2008, 10:15 AM']I didn't read the whole post but something to check is the heat sheild around the header. Mine has a small crack near the front mount that lets it rattle at times, very hard to see (no chance to touch it with out removing the header)[/quote]





Thanks. You are the second one to mention the heat shield. I'll take a look this evening.
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#7

I haven't had a chance to get under the car, but the question dawned on me regarding cracked heat shields as to how you guys ever determined that it was the heat sheild? If it is so hard to get to without taking off the exhaust header, how were you able to diagnose the problem?
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#8

There are several shields under the car, perhaps a nut has come loose on one of the shields.
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#9

On mine I started to push on everything I could with a very long screwdriver until the noise changed/stopped; then I got out the mirror (very small about 1" round on a telescoping shaft) and looked until I found the crack (near the front, under #1 exhaust port).

That's when I gave up until I NEED to fix it; as I cant get in there to put a spot of weld with out removing allot of parts.
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