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When one of the catalysts starts to go bad, pieces break off of the internal honeycomb structure and their bouncing around in the housing can sound like a pretty serious rattle. This is happening to many of the Boxster secondary cats that are now beyond the 7 or 8 year warranty. They are very expensive to replace, like $1,800 apiece. It would be great if one of the aftermarket folks jumped in to make these, but at present its a Porsche-only replacement part.
If anyone has any more positive info on this, please post it.
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