I'm getting alot of resonance with my Corsa X-pipe and Touring exhaust. The noise is noticeable at 80mph, and really unbearable around 85mph. It lessens if you go 90+.

I've got the 3.15 gears so I'm not sure what RPM those speeds correlate to, but do any of you other A4 3.15 Corsa ppl have this problem? Is this normal? Could an exhaust leak be the culprit or do you think maybe the muffler baffles have failed?

Any reponses would be greatly appreciated. Thanks!

 

I owned a 2000 Coupe with a Corsa Indy and X-Pipe with no more resonance than the OEM system. So, your Corsa system should be quiet.

Is the noise in the notorious 1500-1800rpm range??

Did you just install the system, or have you had it for a while and the noise just started??

 

I have the Corsa Touring System and the only way I know of that you will get any resonance is if the muffler is touching the heat sheild. One of the ways this happens is if the muffler gets twisted or cracks a weld at the inlet pipe. Grab both tips and see if one side seems loosser than the other. Another way to spot this problem is if somebody behind you notices one muffler bounces up and down more than the other. But again, my guess is a muffler is making physical contact with the car rather than just being suspended from the hanger.

 

I think that you have a part of your exhaust system vibrating against something at that speed. I've never heard of a Corsa system having resonance.

Tom :steering:

 

I've had the system installed for about two years now. Last summer I started noticing the noise but never had time to do anything about it....I only drove it about 1500 miles last year anyway. I'm busy working on winter mods now and want to fix this problem at the same time. I'm putting it up on the lift tomorrow to change the oil so I'll check to see if any exhaust piece is making contact then. Thanks for your help!


[Modified by jambrin, 10:01 AM 2/7/2004]


[Modified by jambrin, 10:03 AM 2/7/2004]

 

Corsa's do Not have resonance... if you have a vibration at 80 mph.. then it's something loose...

 

I think you guys are right. I looked at the exhaust this sunday and I think at least one or possibly both mufflers are either hitting the heat shields or the muffler tabs (stick out the back of the muffler hanger) are contacting the car body. I am gonna try putting some washers under the muffler hangers to lower the mufflers down a few milimeters. Hopefully this will help!

 

That's exactly the fix GM reccomends in one of their TSBs for the stock muffler.

 

Well the exhaust is not touching any part of the car, so that is not the problem. I've taken the exhaust and x-pipe off completely and re-adjusted 3 different times to no avail. I even put 5 washers on each exhaust hanger so that the mufflers are hanging quite a bit lower, but it did not help. I contacted Corsa and they said to check the over-axle pipe on passenger side possibly making contact with the transmission or car body...NOPE not it either! :banghead: :mad

I put the car up on the lift again today and had my brother hold 2400 RPM to re-create the noise. The noise is definelty still there and the car doesn't have to even be moving to hear it, all you need is 2.4K to 2.6K RPM. I put on my mechanics gloves and pushed/pulled the exhaust while he was revving to see if the noise would subside...NOPE! :banghead: It's driving me :crazy: The funny thing is you cannot hear it outside the car, it is a low frequency BOOMing noise that can only be heard in the cabin.

My only choice now is to take the car to Berea, OH (home of Corsa) to have them look at it. They agreed to look at it for me, but it's about a 4.5 hour drive from Lexington, KY. What do you guys think? Anything else I can try?


[Modified by jambrin, 3:55 PM 2/22/2004]


[Modified by jambrin, 5:44 PM 2/22/2004]

 

have corsa indy wihout cats. not resonance at all.

like the others say, make sure the mufflers aren't hitting the heat sheilds or part of the frame.

otherwise, call corsa and have them replace them.... lifetime warranty.

 

Sounds like you have done all that you can. Corsa has had some product where welds broke. Mine did it on the inlet flange. I'm wondering if you had an internal weld break. Also check the welds on the inlet and outlet. All it takes is a very subtle crack. After that last check I guess I would make the drive.

Sorry. It sure can be frustrating!

 

Updated INFO:

I went to Corsa in Berea, OH. today (4.5 hour drive, whew!). When I arrived I demonstrated the sound to Paul Santiago, which suprised him because he had never heard a Corsa exhaust make that type of noise. Well, that's because it doesn't! Corsa removed my touring setup (which they confirmed that I had properly installed) and flow tested it. Results = 87%, same as when manufactured new. They also tested the car using both a brand new touring exhaust and then a bone stock 2004 exhaust....noise STILL THERE :banghead: It sure sounds like exhaust resonance, but it sure isn't that! :eek::cry


The only thing I can think of now is that the noise is being produced by something in the drivetrain (gears, transmission, driveshaft/torque tube). However, it can't be the gears as the sound is re-producable while the car is in 'N' or 'P' and not even moving! I'm thinking: transmission :eek::eek: I guess I will actually be calling Phil at DynoTech and getting that Rossler tranny!

On the other hand, I can't say enough good about Corsa and their folks! Wow, their customer service is so wonderful that it is beyond belief! :D It was not even their exhaust that was causing the problem, and they worked on my car for at least 2 hours for FREE. Not only that, they took my embarrassingly dirty touring system and polished it (not only the tips but also the muffler cans) to a beautiful shine before re-installing it. To top it all off, they gave me a Corsa hat and C5 poster, and Paul thanked me for bringing the car in. I feel like I'm not worthy! Truely a customer oriented company with a great product to boot! I'm going to post this Corsa experience in a seperate thread because I want everyone to know how well I was treated. Oh, I forgot to mention that Paul gave me a very :cool: tour of the plant and I got to see a few new GM vehicles with prototype exhausts they are working on for 'em!

 

Sorry to hear your still having a resonance issue. The only exhaust system sold with the exception of OEM that has ALMOST NO resonances are Corsa's. Their engineers have worked with GM's. I'm glad they took the time to sort out your problem.

I wonder how many other manufactures would or could have done what Corsa did for a customer with a 2 year old performance part?

Good luck hunting done that resonance, I know how annoying they can be. It can literally ruin your driving and ownership happiness.

Kudo's to Corsa.

Tom

 

Hope you gave those guys a big tip!

 

" low frequency BOOMing noise that can only be heard in the cabin."

I have the same thing at the same 2400 to 2600 rpm range. Mine came after I put on all my mods. I think it is related to the cam I have.
I got that booming resonance with the stock exhaust, with the Z06 Ti exhaust, and even with the the Corsa Touring system ( though the Corsa had the least resonance). None have any body or frame or other contact. All were installed by me or Forum Vendor tuners correctly.
Mine booms out only under load. Not under light cruise. Very annoying to me, I just learned to shift and rev away from it.

 

Since you have definitely ruled out the exhaust, I'm wondering if your torque convertor is the culprit. Also, it probably wouldn't hurt to check your trans mount real good to see if it's trying to come apart or is flexing/vibrating. HTH

Robert


[Modified by LoneStarFRC, 5:46 PM 2/27/2004]

 

:lurk: