Ok, so what i thought was maybe some differential damage i have come to the conclusion is not. Im left absolutely stumped now.

About a week ago i changed my exhaust from a borla to a stillen. Upon driving home (about 2 hours) i noticed an annoying chatter/clunking noise that would happen whenever i slowed down. Did some researched and i thought maybe the differential was hitting the pipes, checked it and that is not the case. Now im lost.

This noise DOES NOT happen upon initial start up or driving the first minute or so. Then it will slowly kick in louder and harder the longer i drive. After driving for a few miles if i come to a stop and idle, it can be heard and will slowly disappear. Does anybody have any suggestions?

I figure if the exhaust was touching something it would be heard as soon as i start it.

The noise is also louder inside the vehicle then it is outside.

Video isnt the best and doesnt do it justice but its the best i can get as there is really no pattern as to when this noise decides to be loud or not.

http://www.youtube.com/watch?v=mpO-_...ature=youtu.be

 

Can here it best at around 16-18 seconds in the video

 

Bump

 

Still sounds like the exhaust is hitting something, put it back on the rack and shuffle the exhaust around and see if you can re create the noise. Did they happen to lift your car with a floor jack under the diff?

 

nope used a lift. and if it was hitting something would it make that noise constantly?

 

I've had similar problems with exhaust sytems I've installed in the past.
The noise is hard to track down as a "rattle" in one area can travel
to another area.Most times the problem was abount a hanger or improper
insulation or a bushing.It could be a defect in your new system.Was it dropped?
A baffle is loose etc.From what you are saying,noise louder inside the cabin,I'd
think it the problem is in the hangers.