Operator

long time no post - I still have my 944S, 7 years and counting...

anyway, recently I started noticing a nasty exhaust note coming from the back end of my 944 so I decided to investigate tonight while finishing up an oil change and I found my exhaust pipe is pretty much rusted off the body of the muffler. the only thing holding it on seems to be that bracket on the underside of it. check the pics below to see what i'm talking about.

my question is this: what's the cheapest remedy here? I don't really want a new muffler, can I just go to a shop and have them patch it up? what's the best remedy if i'm willing to spend a bit more? thanks!

pics:






(i think the pics ended up looking like some pretty cool abstract grunge photography)

El Commandante

Eeek.. I may be wrong, but with the extent of the rust I dont think its repairable. I suppose you could cut out the bad sections and weld in a new pipe. But someone on here found a new muffler for $50 on ebay that looks like stock for the most part but is painted all black including the tip. I would give that a try

KuHL 951

Time to dump it. It's not weldable at this point. The muffler guts are probably in the same shape as the transition.

Jay W

It looks like someone has already welded on that small piece that goes from the muffler hanger to the muffler. None of my cars had that small piece there, most likely that is the only thing keeping the muffler from breaking off the tailpipe. I had mine rust in half like that and since it did not have the extra support piece the muffler hung really low from its own weight.

I broke out my welder and stuck it back together and it has held for more than a year. Even though it was rotted like yours, they used a fairly thick gauge of steel on the mufflers and there was enough to get it put back together. It isnt pretty but it did hold up. If someone uses a wire wheel on each end of the break and gets creative with a welder it can be patched up. Most shops will probably not want to do it because it may only hold a short time.

Operator

thanks for the info Jay - I definitely wouldn't mind a cheap fix to keep it going for another year...

hmm, anyone selling a muffler?

Keithr726

Check automotion.com I believe Bursch is the most factory like but dansk is close with better build quality.

smlporsche

YEP !

Just took the exhaust off the S2 I'm parting out and it looks brand new.
The car was a "Southern car" i,e, no road salt like you have. and only had 61K on it.
$50 plus shipping and it's yours.
PM me for pics if you want.

I also have the catylitic converter section as well....

Operator

PM sent sml, but after sending it I found a closer one on ebay which im looking into...
does anyone know if an S2 muffler fits on an S?

krystar

anything can fit with a welder

Operator

good point, but you know what i mean: "meant to fit"

schwank

AFAIK all 944 mufflers are the same.

Tom R.

from what i read there are three 944s and two mufflers. I think the turbo is the different one. may be three vs four bolts. not sure.

JohnKoaWood

944.111.041.03 (M44.11) 3 bolt flange (N/A)
944.111.083.01 (M44.12) 3 bolt flange (N/A)
951.111.083.01 (M44.52 -89) 4 bolt flange (turbo)
951.111.041.00 (M44.52 90-) 4 bolt flange (turbo)
951.111.041.00 (M44.52 87-[will fit all turbo cars]) 4 bolt flange (turbo)
944.111.041.03 (M44.41) 3 bolt flange (s and s2)

All things are not the same
All N/A mufflers are the same, that is interchangeable. Turbo cars are interchangeable, however different part numbers are called for by year...

I have DANSK on both my cars, and the fit and finish is awesome, and the sound is an incredible improvement.

Operator

So Eddie has a nice set up that I'm going to buy but I just wanted to get a 2nd opinion about installation. He basically unbolted his whole exhaust system as 2 solid units. Can I just bolt this on or do I need some new gaskets at the manifold and in the middle flange? I wouldn't need to weld anything - right? Also I'm guessing its a good idea to get some fresh bolts as mine are probably pretty rusty (hopefully my hangers will hold up).

Picture below is his setup:


thanks

DarylJ

Bolts and gaskets - no welding. The hangers are easy, and should be fine. If the rubber is good, you'll have no problems. If it's not, you can rig it until you get the proper rubber. Not a big deal. Should be a quick job.

You'll likely end up just breaking all of the bolts getting the old one off. It's just easier to deal with it that way. If things get really bad, you might need to get some sawzall going on.