Rattle, Clunk or Exhaust Ground Out Noise from Rear Underside of Vehicle (Modify Exhaust Pipe)

Some customers may comment on a rattle, clunk or exhaust ground out noise from the rear/underside of the vehicle.

The cause of this condition may be due to the exhaust pipe being close to or contacting the fuel tank heat shield.

Determine if the clearance between the exhaust pipe and fuel tank heat shield is less than 8 mm (0.32 in) in the location shown. If the clearance is 8 mm or greater, no further action is required. If the clearance is less than 8 mm, use the following procedure to modify the exhaust pipe to obtain the necessary clearance.

Exhaust Pipe Modification

1. Raise the vehicle.
2. Measure the clearance between the exhaust pipe and fuel tank heat shield to determine the amount of modification required.
3. Mark the exhaust pipe to indicate the area in which the modification is necessary.
4. Install a stand at the rear of the exhaust which will support the exhaust when the hangers are removed.
5. Remove the floor panel tunnel brace/bolts located at the middle of the vehicle's exhaust system.
6. Remove the three exhaust hangers from the rear of the exhaust.
7. Measure the circumference of the exhaust pipe at the location of the interference
8. Using a hammer, dent the exhaust pipe as necessary to gain sufficient clearance.
9. Measure the circumference of the exhaust pipe again to determine if sufficient clearance has been obtained.
10. Lubricate the exhaust hanger bushings.
11. Raise the exhaust and reinstall the three exhaust hangers.
12. Reinstall the floor panel tunnel brace/bolts.

Tighten
Tighten the floor panel tunnel brace/bolts to 25 N·m (18 lb ft).

For vehicles repaired under warranty, use: