After my son installed DC Headers on his 03 TLp I noted that it made the same wonking noise at certain points that my CLs made after I put on XS Headers. That was solved by wrapping the flex pipe.

Doing the due diligence on this site before this install, I was under the impression that the DC Headers don't have this issue but it sure sounds like the flex pipe. We have access to a lift and wrapping the headers is easy enough but it is a band aid fix that needs to be redone periodically.

Has anyone else had that issue with their headers??

 

are they installed properly? IE is the rear hanger on? were they forced into position or did the bolts line right up? Any misalignment on them will cause a slight stress causing that.

 

Are all the motor mounts good? I worried about installing headers without fresh mounts because the excessive play may cause added stress on the headers, causing cracks or flex pipe issues.

 

The hanger was not properly affixed. Excellent suggestion....Thanks!

 

Yes the mounts are good. I had them checked when we bought the car. Thanks for the suggestion. The mounts are starting to wear on my Type S and that could affect my XS Headers...

 

It turns out that that the bolts connecting the j pipe to the headers lined up but not perfectly. They needed to be forced slightly into place. Could that cause the noise and if so what can be done about it?