Exhaust - Rattle or Clunk Noise from Rear of Vehicle: Overview
BULLETIN NO.: 98-T-41ISSUE DATE: November, 1998
GROUP/SEQ. NO.: Engine-06
CORPORATION NO.: 886602
SUBJECT:
Rattle or Clunk Noise from Rear of Vehicle at Normal Operating Temperature (Replace Muffler Assembly)
MODELS AFFECTED:
1998 Saturn vehicles built after and including VIN WZ217O16
1999 Saturn vehicles built up to and including:
VIN XZ119715 with RPOs LL0 and NC1 (DOHC CA Emissions)
VIN XZ129456 with RPOs LL0 and NF2 (DOHC Federal Emissions)
VIN XZ129407 with RPOs L24 and NF2 (SOHC Federal Emissions)
VIN XZ134512 with RPOs L24 and NB7 (SOHC CA Emissions)
CONDITION:
Muffler assembly may contact the muffler ramp that is welded to the spaceframe.
CAUSE:
The clearance between muffler and muffler ramp may be inadequate. As the exhaust system heats up it expands rearward. This expansion reduces the clearance between the muffler and muffler ramp. If the clearance becomes too small the muffler may contact the muffler ramp. This may occur under the following conditions with the vehicle at normal operating temperature:
^ Driving over rough surfaces
^ Shifting automatic transaxle, if equipped, drive to reverse
^ Launching vehicle in reverse with manual transaxle, if equipped
^ Starting or shutting off the engine
CORRECTION:
Drive the vehicle under the above conditions with vehicle at operating temperature to verify that the rattle or clunk noise is caused by the muffler contacting the muffler ramp. A witness mark may be present on the muffler and muffler ramp at the point of contact If the rattle or clunk noise is not heard coming from the muffler contacting the muffler ramp, road test vehicle to locate the source of the noise and follow the diagnostic procedures in the appropriate model year service manual. if the rattle or clunk noise is determined to be from muffler to ramp contact, adequate clearance should be obtained by installing a service muffler assembly. Follow the modified muffler replacement procedure in this bulletin.
PARTS REQUIREMENTS:
21013078 Muffler asm-Exh (w/ tail pipe) DOHC (LLO)
21013146 Muffler asm-Exh (w/ tail pipe) SOHC (L24)
25517280 Clamp - Exh Muff
CLAIM INFORMATION:
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System using the appropriate Electronic Labor Time Guide and Labor Operation Code L2584, (Muffler Replace).