My exhaust that I installed like 7 months ago is now rattling in first second and third in low rpms. I brought it into the shop today and it wouldnt rattle so they couldnt figure out what it was, so when i was driving home it started again. It only rattles when it gets warmed up, never in the morning and never when its cold or anything. Anyone have any ideas, IM going to bring it back in tomorrow after a long drive to show them what Im talking about, but just thought you guys could figure it out maybe. And it even does it when it idles, and seems to be coming from more of the front end and not near the mufflers.

 

Hi there...

Very simple, Magnaflow has had some problems with bad resonators that rattles
usually when cold/start up. The reason for the problem is bad spot welds
inside the resonator ie. a warranty problem.
Call your retailer or Magnaflow for resolution.....

Good luck

peter
Team M7

562-608-8123

 

Happened to me too and I got it replaced under warranty.

Magnaflow customer service was great in shipping a new resonator to me without even wanting the defective unit back. It just took a few weeks for me to get in touch with the right person. . .

 

How much without warranty... i dont remember getting it also it happens when it is warm not when it is cold or just starting up

 

I've had a Magnaflow on since they first started selling them for the MINI. No problems with rattles. I wonder if this is a recent development in thier manufacture?

 

try greasing the bushings, i had the same problem with my Remus. I took it to my friend's shop, he greased them a little, and now they're fine

 

hey kyle,

that happened to my magnaflow and i was going krazy calling to get a resolution from magnaflow... so then i decided to take a look at it... and well the muffler shop that i took it to had left one of the joining points a lil lose... and well i tied it as hard as i could and it got fixed...

i mean i agree with Peter from M7 but check and make sure they are all tied well before you waste time calling magnaflow... if im wrong well it only took 10 minutes to check....

good luck!

 

Kyle,

What year is your MCS? I have an 05, and had a Magna Flow with a similar noise after I had been driving 5-7 miles. Took it back to installer and they put some metal washers(?) which provided a little more room for the exhaust plate not to rub. No problem since--over 3,000 miles ago. I love the exhaust note and the "trumpets" look right. Nick

 

Hey thanks for the help guys, I actually took it in about 4 days ago and tried to show the guy the rattling, and just my luck it wouldnt even make the noise, so of course he didnt charge me. So i figured it only does it once the car is warmed up, so after work today I took it there right after the drive home, he got in the car and it started to do it, which for the first time ever, made me happy hahaha. So he put it on the lift started moving things around and it stopped doing it. SO hopefully it is fixed this time, he said it was hitting something or something like that he didnt speak very good English, but the best part was he told me the same thing as last time, if it starts doing it again, bring it back, and theres no charge. And i left, so i got it done for free!!! HOpefully it doesnt do it anymore.

 

My Magnaflow is about 18 months old and has rattled on and off since new, it recently gotten a lot worse when the engine is cold and a little better when hot.

Called Magnaflow today and asked them about the problem. They knew all about it and immediately offered a replacment resonator with no questions asked. Even said I could come by their office in Rancho Santa Margarita, Ca and pick it up. Then they checked the stock and they don't have one. Will have one for me in a week or two.

If you have a problem with a Magnaflow resonator, just call them, they will make it right.

 

I have the same problem with the resonator. Had the attachment points looked over, everything tightened, adjusted, etc., and still have the rattle. Have been meaning to call them, would one of you post or PM me a number? Thanks!

 

Yep still not fixed DAMN IT. Should I call magnaflow or go into their shop or something and tell them to fix it, or how would I go about doing this.

 

The rattle will really only be removed when you REPLACE the defective resonator. Don't bother monkeying around tightening stuff, just get Magnaflow to send the correct replacement part.

 

You guys should do (post) a product review - Assume you paid a good bit for the exhaust system.

 

I'm glad I got rid of my Magnaflow before it developed a rattle ... or before a rattle developed in my head.

 

All,

Call this number for Magnaflow:

1-800-824-8664

Ask for technical assistance and explain that you have a problem with what appears to be an internal rattle in your MINI Cooper S resonator.

If it goes like it did for me, they immediately offered to send a replacement, no questions asked. They didn't care when or where I purchased the system.

The only problem will be that they don't stock the resonator as a separate piece. They only make the number they need for the complete exhaust kits. They offered to include a request for additional resonators to be made during the next production run which happens every 2-3 weeks.

If they get some and you live in So Cal you can go by their office and pick it up.

Bill

 

Mine is rattling, too. For those who are experiencing this - where is the sound coming from? Mine seems to be from the middle/rear of my MCS. Nothing is touching any of the pipes as I can tell and the tips are clearing without any issues.

Thanks for the feedback.

 

Mine sounds more like its coming from the front/middle, so I beleive the problem is the resonator, I just hope when i call them it is as easy as CooperSS says it is...

 

Bahamabart,

Review submitted. Thanks for the suggestion.

I also emailed Magnaflow about my issues. I plan on calling tomorrow. Will report back when I know more.

 

Magnaflow's office is closed today. Will try again tomorrow.

 

I got a call from Magnaflow Friday that I could come pick up the resonator.

Drove over to the plant and picked it up. The box the resonator was in was so large I could barely fit it in the MINI.

The reason they were closed on Thursday was the brother of the owner had passed away and the funeral was on that day.

I hope you all have an easy time as I had getting this resolved.

Bill

 

Called Magnaflow. They said they could not assist me. Ask me to call the place I purchased the exhaust (hottexhaust.com). I called hottexhaust.com and they are sending me a new resonator. I sure hope this fixes my rattling.

I will report back once I receive the resonator and have it installed.

 

OK, just had the resonator swapped on my 04 MCS.

A word of caution!!! My system had three main pieces, the resonator pipe which bolted to the cat and had a short pipe extending from it, then a short mid pipe extending to the pipe entering the "race track" rear module.

The new resonator I received from Magnaflow was for a system that only requires two pieces, the resonator bolted to the back of the cat and a much longer pipe extending from it meant to attach to the pipe entering the "race track" rear module. A much simpler setup with one less clamp.

The problem arises as the two piece system apparently has a longer pipe entering the "race track" rear module. In my system that left the new front pipe just a little short of full engagement with the rear. There should be an inch to inch and a half overlap for proper sealing and in my case I was left with about one quarter inch overlap. That left the slots that are in the rear piece (used for being able to collapse when the clamp is tightened) exposed to the open air. The muffler shop I took it to, (glad I didn't do this on my own) just welded the joint and filled up the slots with weld material and all was well.

One hour on the rack, a little welding, the best $80 I've spent in a long time. Sounds great now, no more rattle.

SwingMCS03,
One reason I may have not had any problem with Magnaflow is I told them I have moved since buying the system, lost the receipt and didn't remember where I had purchased it.

Good Luck all,

Bill

 

Update:

I called Magnaflow months ago (as stated above) and they wouldn't assist me. They told me to contact the place where I purchased the exhaust - hottexhaust. I spoke to a guy there who confirmed my purchase and agreed to send a new resonator. Well, 4 months later and no resonator. I have not followed up but will be when I get some time during their business hours.

I did have my exhaust looked at at the place where I had it installed locally. They said the rattling had something to do with the flex pipe. They couldn't help me so they recommended a trip to the dealer. Fine, since I had an appointment set already. At the dealer, the tech indicated he saw evidence that ? (flex-pipe) was hitting the front sway bar. He suggested that I buy exhaust tape, wrap it around the swaybar to get the rattling to stop. Will this work?

In the past 4 months, the rattling has increased, especially when the AC is on. Sounds like change in a dryer. Any assistance will be appreciated.

 

Maybe you should tape up the doofus that recommended taping the sway bar.
There's a problem that needs a solid fix not some patch job.
I had a Magnaflow with the bad resonator.
With a little help from Randy Webb he put me in contact with someone at Magnflow and I got a whole new system under warranty.
They were going to do the resonator fix with me but what they don't tell you is you have to go to on of their recommended shops or you lose warranty AND the shop will charge you $50-60 min just to weld in that resonator.
I said No Thanks and got a bit stubborn about it.
A week later I had a whole new system and shipped the old one back.

I liked the old style tips better.