09/03? That's what I found.....

 

Thanks, you are before the 1/2004 change up on the rear exhaust clamps. These tend to clang when rusted or falling apart. On the Center exhausts is usually the center bushings.

http://www.ecstuning.com/Mini-2004-Cooper-R53-S-Coupe-L4_1.6L_W11B16A/Exhaust/OE/

Center bushing, there are two. They can sag and then the exhaust can rattle.



On the rear hangers check the upper portions, that where they rust on boh sides ( Unless the car has the one ball mod) which the exhuast barrel on one side has been removed. You will need the clamps " For vehicles with production to 1/2004 " There is a left and right side upper and lower clamp.



Check the rear bushings also ( orange red color ) .




I would also check the exhaust heat insulation ( tin metal tunnel) is in place and is not vibrating under exhaust revs.




Thanks.

 

Thanks again. I. got under the car and found that the rattle is definitely somewhere around the mufflers.


The hangars are in great shape, no rust anywhere..


Almost sounds like it's inside the right muffler........

 

Might be the shield cover out side of the muffler housing rusting apart on the inside. Check the muffler barrel on top and for rattles. Rattles under certain revs.

Thanks

 

Hmmm. That makes sense. And the muffler sounds a bit louder than it should.

 

If it's that passenger side muffler, one ball mod it!

 

One ball mod? I'll have to search that one......

 

One tip...
The outer part of the muffler/resistor has a mild steel heatshield....it rusts, and looks bad, but the stock system is stainless steel...
My outer heatshields on the "cans or *****" aka, muffler and resonator were rattling and full of holes...peeled it off...now quiet. The stainless underneath was still shiny and airtight....
Look around...feel for blowby...

 

I think it's inside the muffler.

 

I gotta tell you, this car is very clean underneath. I'm surprised how clean it is for a 10 year old car.

 

That does not look like the stock Cooper S muffler. Looks like and aftermarket one? And sounds like it separated inside.

 

I agree. I see they sell some for $225.....

Im betting it's one of those.