T-Roc Exhaust Flap Issues Causing Excessive Noise

I had a very similar issue with my 2021 T-Cross last winter. Having some experience with exhaust system problems, I recognized those symptoms immediately. The loud noise during cold starts was exactly what I experienced. The exhaust flap actuator had failed, causing the flaps to stay in one position. This affected the engine performance and created that abnormal exhaust noise you described. Took it to my workshop where they diagnosed a faulty flap actuator in the exhaust system. The repair included replacing the actuator and recalibrating the system, which cost me 190€. After the fix, the exhaust noise returned to normal levels and the engine performance improved noticeably. To better understand your specific case, could you share: Current mileage on your T-Roc? Does the noise change when accelerating? Have you noticed any changes in fuel consumption? Any other warning lights on the dashboard? Getting this information would help determine if your issue is identical to what I experienced or if there might be additional exhaust blockage concerns to check.

Thanks for the detailed response. My T-Roc just had its latest service last month at 27761km. The noise definitely changes with acceleration, becoming more pronounced. The exhaust flaps seem to be stuck, as the sound stays consistently loud regardless of driving mode. The dealership quoted 230€ for a new flap motor and actuator replacement. Before committing to the repair, I wanted to check if this is a common issue that might be covered under warranty, since the car is still relatively new. No other warning lights are showing on the dash besides the exhaust system fault. I noticed the exact symptoms you described, the loud cold starts and affected engine performance. Good to know the repair resolved these issues in your case.

Thanks for the additional details. Your symptoms match my T-Cross situation perfectly, especially the loud noise change during acceleration and the stuck exhaust flaps. Since your T-Roc is a 2023 model with only 27761km, this should definitely be covered under warranty. My repair invoice specifically listed the faulty exhaust valves and flap motor as the core issue, and these components typically have the same warranty coverage as other powertrain parts. Quick tip from my experience, make sure they check the complete exhaust system during the repair. While my main issue was the flap motor, the technician also found a minor exhaust blockage that contributed to the poor engine performance. Having both addressed made a significant difference. After my repair, it took about 100km of driving for the engine control unit to fully adapt to the new flap motor settings. If you get it fixed, give it some time to settle in. I suggest pushing back on that 230€ quote and having them check the warranty coverage first. These exhaust repair issues are well-documented on newer models.

I appreciate all the feedback about the exhaust repair situation. Just got back from the dealership and you were right about the warranty coverage. They confirmed the faulty exhaust valves and flap motor are fully covered under the factory warranty, so I wont need to pay the quoted 230€ after all. The technician did a full diagnostic of the exhaust system and found exactly what you mentioned, a minor blockage along with the failed flap motor. They are scheduling the complete repair for next week, which includes replacing the actuator and clearing the blockage to restore proper engine performance. Really helpful to know about the 100km adaptation period after the repair. Will definitely keep that in mind and avoid making any quick judgments about the exhaust noise levels right after the fix. Thanks for helping me avoid an unnecessary repair expense and for the detailed insights about your similar experience. Will update once the repair is completed to confirm if it fully resolves the cold start noise and performance issues.