How To Remove Rusted Exhaust Bolts Boxster & Cayman 986 987
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- Опубліковано 25 сер 2024
- How to remove the exhaust bolts that join the exhaust headers on the exhaust to the catalytic converter.
This is a common Boxster fault and when they rust the gap between the two exhaust parts will allows gasses to escape causing a terrible noise.
Boxster Parts:
Gasket 996 113 113 00
Bolts 900 074 287 02
Nuts 999 084 052 02
Thanks for the video and the comments. Had this very issue as well except that the nuts were still in place without hexagons. Used a nut splitter and chissel to free the bolts. Used heat and a swedish pipe wrench to press out the bolts. A little under an hour work for one side.
I just bought two Boxsters :) Both were non-runners, been fixing them up over on my channel. Really enjoying your format and attention to detail. Subscribed! Will be following with great interest. Cheers.
Glad you liked them Julian. Thanks for the kind comment. Your Boxster vids were cool and I've subscribed to see if what you get up to!
Just been though this on my Boxster, heat is the qickest and easiest option! I cut down the middle removed the manifolds, heated the flange then punched it out.
You should regularly replace those together with your cabin air filters, so they won't rust away over time ;)
This needs heat. Better to snap the remains of the nuts off. Then using a MAPP gas torch (available from good DIY stores) heat up the stud. Before doing so though, have a punch ready to knock it out hitting it from the thread side. Once the stud is glowing, tap it out with a hammer. I actually used a small socket and a few extension bars. The socket fitted perfectly over the threaded bit of the stud.
If the old nuts are badly corroded, heat them up too and then hit them with some freezer spray. Watch how the thermal shock disintegrates them before your very eyes.
Just been out for a burn up in my 987.2 3.4 and I think this has just happened exhaust blowing and a bit of a rattle !
Need to jack in up and see where it's blowing , I hope this is the fault and not something else , good clip this has put my mind to rest a bit ,
Just replaced my exhaust, those same bolts...oh Jesus, I had to cut off the nuts with a grinder, then torch the bolts and hit them about 200 times. And I just got my 2ND COVID shot yesterday, arm is hurting and a slight fever. I had 3 out of 3 rusted shut inside the exhaust. Then the old gasket fell into the catalytic converter, good grief. I should've saved this for an exhaust shop!
I don't envy that job. Had a few stuck bolts but never like that! Thanks for another great video!
Glad you liked it. Thanks for watching!
The fun of removing bolts, I'd suggest spraying it with pb blaster or similar any chance you get to let it work. I had a tough bolt that wouldn't budge even broke a socket on it.. sprayed it a couple times during the week and by the next weekend came out nice n easy. Great vids!
Yeah, they were stick good! Thanks for the tip!
drop of heat - mapp gas if you've no oxy/acet - then largest dia drift possible to suit.
every diy guy needs at least mapp in his toolbox for rusty nuts/bolts etc.
Oxford is my university place number one, best place ever, brilliant.
mine has triggered a enginewarning light with the codescantool saying the postcat oxygensensor detects a lean air-fuel ratio, so i guess it pulls ambient air into the exhaustsystem through a gap like this which causes it to get this code.
+TheWolvesCurse Yeah, could be. Have you had a look under the car?
Road and Race not yet for that problem
Using Colbalt drill bits helps too, had the same issues on the de-cat flange on my RX8. Didn't try all the hitting though as knowing how the studs are pressed in I thought I'd likely do more damage to the rest of the exhaust/mountings.
Porsche must have sourced the cheapest steel nuts on the planet. Mine look as bad as yours but while they're still holding on I'll leave them. Having soaked many things in penetrating XYZ I actually think it has little if any effect apart from the placebo one.
Note to Porsche: -Stainless steel, not a new invention nor an overkill on a Premium car.
I completely agree. Why make a stainless exhaust then connect it with cheap nuts! Couldn't have saved Porsche that much money. Thanks for the tip about Colbalt bits.
Thank you very much!
I have this exact issue on my 987 slightly different flanges but I'm sure it'll be as hard to remove, hence why I'll taking it to a garage after failing miserably!
Well, at least you tried!
Having the same issue with mine, this video concerns me lol
How did you cut the one on the top? The room was so tied and my cutting tool didn't fit...
have you done this on drivers side yet, cannot for the life of me get access to top flange bolt, removed other too with heat and air hammer, but do you have any advise on getting to top stud, thanks
you’ve gotta remove everything
What a pain in the ass this work must have been!^^ Didn't you want to upgrade the exhaust. This one looks in good condition but it's not really shiny anymore. There are some nice after market exhausts out there :)
Yeah, it was a real pain, but a at least I learned something. Would love to have replaced at the exhaust as the stock 986 S one is a little muted. The system I wanted was over £2000 so may just replace the muffler if I can save enough cash!
10.9 grade steel x__x those studs are mechanically welded in there. Bit of an ordeal to even get them to move.
Damn, I got the same issue in my 987 Boxster and I thought I could get away with doing it myself. Should I pay the £300 or try to do it myself in a garage such as this one?
Hello we what bolt size did you
Use thanks
Who hasn’t owned a rusty Porsche exhaust system?
Makes me want to just buy all new pipes and be done with it. 😆
Or heat it up with a gas welder
It takes 10 minutes when the nuts are corroded off.
Sometimes it’s better to just pay some one who knows what they are doing.
This is a oxy/acetylene job with a very small gouging nozzle a very steady hand and a punch providing the bolts are mild steel not stainless ... shouldn't take any longer than 15/20 mins to knock them out , without heat it's going to be a sod of a job and I can see why it took hours to do .. I will report back with how I have got on ..
So how did you get on?
hugh3sy7
I used a friends ramp and he had a set of oxy/acetylene, the nut heads had totally rusted off , heated what was left of the bolts cherry red and then punched them out , to be fair the job took about a hour , this car on clip is a 986 mine is a 987 , replaced new stainless steel nuts blots and spring washers new gaskets job done , having the heat is the key to doing this job and a car ramp , ordered pack of 8mm x40 mm stainless bolts plus the stainless nuts off ebay ...
Gaskets from europarts
Done 1000miles since done all good 😊