2000 OBW.

 

I just pulled the engine and replaced the clutch this weekend and now I've got some new exhaust rattles.

Obviously exhaust rattles are pretty common with these subarus and I've been under the car before and used hose clamps to tighten the loose sections of heat shield.

 

The new rattle (well it's actually two distinct rattles that happen at different RPM ranges) sounds deep and like it's coming from under the stick shifter. This rattle happens in low-rpm 2nd gear. The other rattles are higher pitch, more 'tinny' sounding like the typical heat shield and happens in 1st through 3rd low rpm ranges.

 

I've just got out from under the car and everything feels tight, took a screwdriver handle and tapped all along the exhaust pipe; nothing noticeable.

 

I guess my main question is if anyone has ever experienced new exhaust noises after removing/reinstalling an engine.

 

The other thing, when I dropped the exhaust manifold from the heads I left the exhaust dangle from where ever it attaches further back, this would be near the flange. I wonder if I stressed that joint?

 

Also, while I was shaking the pipe back and forth I noticed the transmission and drive shaft moves a lot also. The exhaust is bolted to the trans and the trans is on a rubber isolator but I never noticed this much movement before. Could I have broken something jacking up the trans while removing the engine?

Did you loosen the trans mount when pulling the engine? I'd double check to make sure all the bolts are connected.

 

I had a weird rattle after doing my AWD swap and turned out I didn't tighten the bolt for the pitch stop mount where it bolts to the chassis.