Tapping Noise Bottom of Passenger Side A Pillar 2005 997 Coupe

[afishkind]

I have developed a tapping noise in my 2005 997 Coupe where the passenger side A Pillar joins the dash nearby to the windshield.

I have done the following:

1. Removed glove compartment and felted everywhere.
2. Removed speaker covers, defrost vent plastic, and A Pillar trim - cannot isolate the noise.
3. In the right front wheel well ... removed trim and taped up any moving parts with sticky AC tape.
4. Made sure the ventilations ducts are solidly connected.
5. Removed any possible offending plastic/rubber from the frunk.
6. Gummi Pflegged all seals in the region.
7. Used Pedro Wax underneath the window seals.
8. Took the car to a Porsche window specialist who said the noise was not due to the windshield and he would even reseat the front windshield he was so sure.


I put the phone down in the region of the tapping sound and recorded the following audio:




The picture in the audio shows the area of the noise ... and where the phone was lying face down recording the audio.

Yes ... I should just turn up the radio or enjoy the AWE exhaust ... but the noise is killing me. Predominantly makes the noise when going over bumpy road. Local suspension expert says it's not the front right suspension.

Thanks for any help ... I've tried everything mentioned in the forums and no dice. Thanks in advance for any advice.

[afishkind]

Questions I've been asked:

AC on, FAN on --> yes noise is present
AC off, FAN on --> Noise is present (press the "AC OFF" button but leave the fan on low)
AC off, FAN off --> Noise is present (press the "AC OFF" button, leave it for a while to stabilize temps, then turn the fan off all the way)

Next diagnosing steps after AC, does it happen while sitting stationary? No

Or only when moving? Yes
Does the noise increase frequency with engine RPM? No
Only happen at certain RPM's? No
During idle? No

[afishkind]

I finally gave in and took it to a Porsche dealer. They had the nerve to call me and tell me they had fixed the noise ... that they had done 7 hours worth of labor. I arrived at the dealer ... started up the car ... noise was still there louder than ever. I politely refused to pay and left. They provided no explanation as to the cause of the sound or why they thought it was fixed.

I'm up for more suggestions. Thanks for your help.

[Uwon]

Have you tried putting a stethoscope/phone on/by the fuel filler tube from the trunk side? Read somewhere that there is a valve nearby for the fuel return and/or fumes being drawn back into the engine intake.
Good luck.
Cheers,
Johan

[afishkind]

Uwon thanks for the tip I'll check it first thing in the morning.

[FPB111]

Go to the fuel line vent replacement diy in the Pelican tech diys to see this valve.

[afishkind]

Using greatly appreciated advice, I have been unable to find the source of the tapping noise. It has grown louder and more constant. Using a stethoscope, and ruling out locations where I have used teflon and felt tape, I have decided the tapping is coming from behind this metal plate at the base of the passenger A pillar:




Does anyone know how to access the inside of this metal plate? It appears welded in place. Thanks in advance.

[FPB111]

What happens when you disconnect one of the electrical connectors? Do you have rain sensing? What option would have electric connected to the windshield? Do we have auto defrost?
Is that evidence of arcing on the wire to the connector on the right?

[FPB111]

TSB 4/99 6420 Body windshield noises might have the answer. Go to Renntech.org TSBs and search for the TSB. It mentions a tapping noise fix using rubber cord.
You should have have taken your windshield guy up on his offer.
The tapping complaint was in a previous post somewhere? The TSB fixed it for him.

[afishkind]

FPB111 - no difference when electrical connectors are disconnected. No arcing.

Interestingly ... here is a video in a Ford Flex making the same exact sound at the A Pillar and Dash:

[FPB111]

Did you get a chance to check out the TSB?

[afishkind]

I did ... taking it in Monday to check on the window .. thanks for the tip.

[afishkind]

Thought I would post the solution to this mystery. After removing the right fender ... it became obvious that there had been some repair done at the seam pictured in the red circle below .. probably some accident that had not been known to the previous owner ( the third owner ) and not reported on Carfax.

Applied over the seam that was apparently welded was some substance .. something akin perhaps to JB Weld. Some of it still remaining in the second picture. After scraping off the substance, the tapping/stress release sound in the video at the beginning of this post vanished. The car is put back together with no more noise. Thanks to all who gave advice.

[FPB111]

That looks like seam sealer. Hard thick "paint" for sealing welded seams.