hurricanesteve

Part I: While NickS owned this car he had an APR exhaust put on by Don McGill Audi. From what I understand, they sent him a prototype by mistake that didn't fit. I understand they shipped him another one, paid for the install, and paid to have the prototype returned.

Part II: According to Nick, the exhaust developed a resonance after a short time, and the guys at McGill tightened down a clamp. This resolved the issue, but they recommmended that the exhaust be welded together to fix it permanently.

Part III: I buy the car from Nick. I love the sound of the exhaust, the fit is not perfect at the tail pipes...they sit offcenter to the left. I can live with this, however. Over the last couple weeks, the exhaust got louder and developed a 'buzz'. Also, the sulfur smell has gotten very bad under acceleration.

Part IV: This morning, I drive to a muffler shop to have them look at it and see if they can clamp it better (it is very obviously leaking at every single fitting), or if they will weld it. $80 to weld it, I'm told. Okey-dokey. While I'm under the car, I take a second to glance at the flange where the downpipe attaches to the cat. I notice one of the three bolts is missing...the one most driver side...hardest to see. I ask if they'll replace it and tighten the others. $100 total. Fine. Immediately upon sitting down in the waiting area, the mechanic comes flying in and says there is a bolt in there but it is broken off. I follow him back out and with just the right flashlight angle, you can see the head of a bolt. He says he can get it out and replace all three with stronger bolts...$210, now. Fine. I'm a little disturbed, tho, obviously.

Part V: When they are finished, I drive off and notice that the exhaust is MUCH quieter. It sounds very good. However, as I reach my office building (i've driven the whole way w/o the a/c so I can listen...alternately opening and closing windows), I hear the 'buzzing' or 'rattling' sound. It happens around 2500 RPM...goes away at higher and lower RPM. As you can imagine, I am praying to all that is holy that it is a heat shield or some such...christ, I'm having and ulcer over this.

I have not contacted APR, yet. I'm not sure what I'd say to them. I am most worried that this exhaust will cause damage to an expensive part, like the turbo...and I'd have to eat it. I think I'm in limbo because I neither bought the exhaust, nor originally had it installed. Of course the muffler shop guys don't think anything will be damaged, but their expertise is quite limited.

I think I'm going to take it to the dealer (McGill) to diagnose the rattling sound.

Anyone got advice?

eh-fow

My Neuspeed/Borla had this very annoying rattle for a while right around 2500-3000 RPM. I had the car jacked up and the mechanic (Todd at AWE) started banging around. At first he though it was something up in the cat that was ratling but he eventually traced it to a little brace that sits at the bottom of the downpipe right before it goes into the flex-pipe. Once he tightened the clamp the rattle stopped completely. If you have access to jacks go down there and with your hand (make sure it's cool) bang around on the downpipe and see if the rattle is coming from the brace. If you don't have good jacks available try to force the tips in the back around (you won't break the exhaust) and see if you can reproduce the rattle. I would assume though, just because of your description, that it is that fricken' brace.

Also, you might want to see if anybody w/ a B&B triflow exhaust has had similar problems. The APR exhaust is nearly identical (and made by B&B) so if others have had this problem they may be able to offer some advice.

HTH,<p>Dan
99 1.8TQMSX K04 Santorin
<img src="http://pictureposter.audiworld.com/AudiWorldPics/2000/dh-sig.gif">

CP

<p>Cy...Pearl '97 1.8TQMS, APR: v3.1-exhaust-SS lines, UUC, Neuspeed, H&R Sport, Bilstein, AEZ Bimos, AVS Sports, ATE Powerdisc, R4S, Valvoline SynPower, Mobil 1, Autometer, K&N, Air Box Mod, Aluminum Trim...66.8K and counting.

LCP

The broken bolt thing does really suck, though.<p><img src="http://pictureposter.audiworld.com/AudiWorldPics/2000/LCPawsig1.jpg">
- Lance (corporate lawyer type turned track time junkie)
"I can't stop apexing"

BCA4

<center><img src="http://pictureposter.audiworld.com/AudiWorldPics/2000/Stebro_Exhaust.jpg"></center><p>Hi all,
I have got similar problems with my Stebro. I currently have a loud resonance that develops around 2500rpm and stays through to just over 3000 rpm. Pretty annoying when the cruise is set at just over 100km/h. Hopefully, its like Steve's and is just leaking somewhere and needs to be sealed better. I certainly hope so as it can be pretty loud!

The more serious problem with the Stebro is fit - as I have indicated in previous posts. I have now spoken with Andy at Stebro (I think he is one of the two brothers running the company, the other is Dan?). He asked me where the exhaust was hitting and I explained. He asked for pictures and I sent the above image from a Stebro exhaust install on a ~98 2.8 30V Quattro that I found in the 99 photo archive. I have indicated in green the area where the pipe is contacting the car. Basically, Andy said that they originally fit the exhaust that I purchased on a 98 A4 1.8T Quattro Manual and that the frame member in the picture did not exist on that car. Is this correct? I find that hard to believe as it looks to be the part of the quattro drivetrain and was surprised to hear Andy say that I have the rear end of a 2.8??? Can anyone shed some light on this?

Anyway, after I get back from holidays, I will visit a local muffler shop and take pictures of my car to send to Stebro. They sound supportive and I hope they will work with me to make everything right.

Steve, hope your rattle turns out to be something minor. I don't expect it will cause any damage anywhere else in the system.<p>Andrew
'00 1.8TQMSX Ebony Pearl/Onyx, Debadged, Tinted, H&R Coilovers, P7000SS, APR, Stebro

hurricanesteve

is that you mention a flexpipe piece. The stock exhaust has a flex joint...the APR exhaust does not. The hanger right at the bottom of the downpipe has a spring looking thing that I imagine will allow some extra movement, but anything that flex joint provided is gone. I hope that it isn't a big issue.

I will bang around on it tonight. I have ramps and jackstands, so those will have to do. Actually, I'm thinking I will take it back to the muffler shop and see if they'll put it on the lift and help me first.

thanks a million for the advice...

tird

I had the same exact trouble. I had my APR exhaust installed by Midas. Big mistake on my part. Midas clamped my flex joint and ruined my down pipe and I had to get a new one. My exhaust made the same noise you're talking about. An annoying heat sheild type rattle at around 2800-3000 RPM. Any lower or higher it would not do it. My exhaust also shifted all the way to the left and was bouncing off of something underneath my car. I had my exhaust removed and reinstalled by a garage that specialized in European performance race cars. They said that they don't know how midas could have even let me drive off with it installed like that. They said that it was one of the best fitting aftermarket exhausts that they have ever installed. Well, anyways, they reinstalled it and there is no more rattle. It did shift itself back to the left a little bit, but I took it back and they put a couple of pipe clamps on the hangers so it couldn't move its way back to the left. It has been dead center for a month now.

Hope this helps.<p>Ed
99.5 1.8TQMS, APR v3.0, APR Exhaust, K&N, MM Spyders, LLtek Induction Kit, MC BPV

hurricanesteve

I don't think mine can be centered unless the rear hanger itself can be adjusted...

The muffler and bracket (welded to the muffler) are positioned such that it is pushed ALL the way into the hanger (rubber piece). You cannot move it at all...it can't be adjusted (unless, as I say, the hanger itself can be moved).

read my newer post (coming next) for more gory, bitter details.

nick n

Ditto that