Hi all,

My nearside PSE backbox has been rattling for some time and has been annoying the hell out of me. I'll replace the full system soon, but for the moment just wanted a quick fix to stop the rattle.

I managed to secure a replacement box from ebay (via a fellow 911uk member) with the intention to cut it to pieces and see if it was indeed possible to fix. Figured it cant be that hard!!

So with a little help from my mate (well was 99% him to be fair) we disassembled the PSE, cut it to pieces and welded everything back together.

1. Ground off surface currosion and cut open box. (Its double skinned so you do need to cut fairly deeply.



2. Open up the backbox like a can of beans and its easy to spot the source of the rattle! Broken baffle.


3.Weld it back together. This was by far the toughest part as the metal is very thin.


4. Seal the weld with to ensure there are no holes / leaks, and refit to car.


Fixing the PSE took about an hour, and removing / refitting probably took another 2 in total, so all in all a good afternoons work!

Works a treat, no rattles and the car sounds great again.
(I shall be nicknaming this mod the holder hack )

 

Superb!!!

That is exactly what my 2006 is suffering from. Now I need to find someone who can do that for me as I am not an expert at welding.

Yves

 

I always wondered how the inside of the PSE can was laid out. Thanks for answering that question!

 

Elliot,

How did you disconnect the vacuum line at the actuator? Last time I looked at it, I was puzzled on how to remove the line from the muffler.

Thanks
Yves