Screaming brakes and Exhaust repairs

11:43am
Took Ruby in for the SCREAMING brakes on Tuesday and my service guy said they'd be replacing the Pads and Rotors. I pick it up at lunch today, so I'll try to get more details about it and hopefully they'll be quiet now.. I also noticed a rattling sound that seemed to come from the exhaust system on startup. They confirmed it was indeed in the exhaust and have ordered parts that probably won't be in till next week.. Wanna get more detes on that too. Said they had a "Service Message" about that problem. So now we have Recalls, Technical Bulletins, and Service Messages? Hadn't heard of the SM's before this.. Anyway more to come.

1:44pm
For the Brakes, they replaced both rotors and pads on the front brakes and referenced TSB # 15-0030. Hopefully the brake screaming will be gone now. So far for the exhaust noises, they found a bent catalyst pipe (A - Pipe Muffler Outlet - Front) which caused a "slight" exhaust leak under drivers seat. They refer to TSB # 15-0022. They tried to adjust the Exhaust cat pipe but the noise continued. They then replaced the pipe as per the TSB and it verified as ok. They also mention SSM #45172 for noises coming from the Internal Resonator and so they've special ordered a muffler Resonator assembly and will let me know when to bring it back for installation... I guess this is what I get for getting a "Point Zero" release!

What noise were you experiencing with the bent cat pipe?

TSB #15-0022 is in regard to a leak on that pipe, it shouldn't create noise. But maybe it does.

I had them replace my brakes today too. I took it in last week but they were out of parts. I guess they've been replacing a lot of them. My car was made a day before the end of the issue, 2/9/15. So far they are quiet but I've only gone 7 miles. First thing in the morning is when they were worst but also pulling in my driveway after an hour commute coming home from work. I'm confident they will be ok now after hearing others results.

crowemag55 said:

11:43am

They also mention SSM #45172 for noises coming from the Internal Resonator and so they've special ordered a muffler Resonator assembly and will let me know when to bring it back for installation... !

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I am having this done today. they ordered the part last week. I have been dealing with the loud ass start up noises and loud engine braking for over a month now.

Service guy just called and said it was fixed. heading over after work to pick it up.

Zodiac said:

What noise were you experiencing with the bent cat pipe?

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Initially I took it in for a loudish ticking or knocking sound during the higher start RPMs that went away after the RPM's came down to normal idle. Then a few days later it morphed into a sort of rattle at first start after it came down to normal idle but the rattle didn't last very long..

I didn't know it had a bent cat pipe so don't really "know" if I heard the leak associated with it.. I sure as hell don't know how it got bent either.. Since there's a TSB on it, I'm assuming they know it came from the factory that way..

It also had a sound like bb's or ball bearings rolling around in the right back end on hard braking, but that was hard to reproduce. That seemed to happen intermittently even though I'd try to force it.. Was weird. They think it's part of the upcoming resonator replacement so fingers crossed that they're correct...

I too had the exhaust rattle upon startup. I discovered it was from the loose ball clamp located directly underneath the driver's seat as seen in the TSB. After tightening the crap out of the clamp, I no longer have the exhaust rattle that left me perplexed for so long. The dealer couldn't figure it out either. Also, my resonator is deleted with a H-pipe welded in. Be sure to tighten the crap out of all your clamps. I hate clamps for this reason. You can actually reach the ball clamp bolt and tighten it with a 13mm socket if you are long armed so you don't have to lift the car.

As to the brakes, they sounded like a garbage truck until I got the new rotors as per the TSB.

Here is my old rattle noise on startup at the 12th second of the video:

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Ivan, thats the sound I had, but mine was worse.

Confirmed the replaced my entire exhaust from the cats back, including the suitcase. I guess they did that versus cutting and welding in the new suitcase. work order says "replace resonator/exhaust assy per SSM#45172"

Anyway, my noise is completely gone. And as a side effect, my highway MPG jumped from 24ish to 28ish. Not sure if the mpg is a fluke, but i never have noticed it saying 28 after a fill up and highway cruise.

Wonder if part of the rattle was a collapse of the muffler element causing serious restriction.

Either way, I am a happy camper.

GoBlues38 said:

Ivan, thats the sound I had, but mine was worse.

Confirmed the replaced my entire exhaust from the cats back, including the suitcase. I guess they did that versus cutting and welding in the new suitcase. work order says "replace resonator/exhaust assy per SSM#45172"

Anyway, my noise is completely gone. And as a side effect, my highway MPG jumped from 24ish to 28ish. Not sure if the mpg is a fluke, but i never have noticed it saying 28 after a fill up and highway cruise.

Wonder if part of the rattle was a collapse of the muffler element causing serious restriction.

Either way, I am a happy camper.

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It will be interesting to see if my MPG gets better then. I'll have to keep an eye on it. Part are supposed to be in late today, so next week I should find out.

crowemag55 said:

It will be interesting to see if my MPG gets better then. I'll have to keep an eye on it. Part are supposed to be in late today, so next week I should find out.

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Ruby goes in for the final parts installation tomorrow. Hopefully she'll also be back out tomorrow!

I have my appointment for next Wednesday for the brake TSB and for the rattling exhaust. They are ordering the parts for the brakes, will have to wait and see on the exhaust.

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crowemag55 said:

Ruby goes in for the final parts installation tomorrow. Hopefully she'll also be back out tomorrow!

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Ruby did come back yesterday for the exhaust repair. Per SSM #45172 they replaced the "Resonator Muffler Assembly", Part# FR3Z*5230*C. So far it's had 2 quiet startups! That part number appears to be the Suitcase muffler. The Screaming brakes do seem to be fixed. They've been quiet since I got it back last week. For that problem they replaced the front pads and rotors.

My brakes were replaced today under the TSB and exhaust assembly should be replaced on Friday. Hopefully my noise issues will be over soon.

I have my calipers painted and the brake system has been screaming for the first bit after sitting for a while.

Any idea if the dealerships will give me crap for painting my calipers?