RUSTED EXHAUST BOLTS 981??

[StaffsVillan]

Hi all.,
Hope you don't mind me picking your brains, looking at replacing the rear exhaust for at Carnewal GT Exhaust, thought it would be a simple job, but as you know that never transpiers, so I thought it might be a good idea to start to remove the exhaust this weekend, in preparation for your replacement one.

However I've a problem with the 4 bolts that connect the rear exhaust to the Cat/manifold. Is this a real worry??

As you can see from the picture, the nut has rusted and basically disintegrated (which seems to happen alot after reading a number of forums) and also on the cat/manifold side it's completely round??

Any suggestion on how to get theses undone??
If they are cut off flush to the flange, will the remainder of bolt knock through towards the cat/manifold??
Thanks in advance for advice ??

 

[Motorhead]

As you say Richard, a common problem with modern Porsche exhausts. A liberal application of freeing agent (left to soak) for starters and the application of heat if necessary should get things moving, but you may have to face the fact that the bolts will shear.

I think that the bolts will knock through with some effort, though you'll need to provide something heavy to react the impacts. There was a post on this very subject recently which should be useful:

https://www.porscheclubgb.com/forum/tm.aspx?m=409165

Jeff

 

[StaffsVillan]

Thanks Jeff
It came up with that thread after I posted, surely porsche should make it a bit simpler to remove the exhaust bolts/studs, at least with something that doesn't simply rust away to nothing ??????

 

[Motorhead]

Yet another example of "value engineering" Richard. Even manufacturers of so-called premium cars aren't exempt.!

At least you don't have to remove the exhaust manifolds. Apparently the studs in the heads are prone to seizure and shearing off - not a fun job trying to get steel studs out of an aluminium head.

Hope you have success in removing your flange nuts and studs.

Jeff

 

[GordonT]

I’ve just posted on the forum thread above and asked why we don’t use brass nuts on carbon steel.
Opinions/comments appreciated!

 

[3286ib]

Grind off, drift out the interference fit offending stud. Banging can damage O2 Sensors. Fit S/S 8mm marine grade nuts and bolts.
Good luck a real PITA.
Ian


550 Anniversary
2017 S3

 

[StaffsVillan]

Just a quick update, bolts all sorted, combo of consentrated heat & gripper sockets, but you're right it's a ball of a job. Exhausted ordered from Gert and fitting Thursday. Looking forward to the new sound track ??????????
Might look at replacing the nut with a brass one or make the effort in changing them every 12 months ????????