MacinTek

Week before last, I was driving home from a client and I got about a quarter mile when CLANG!!! SCRRRRRAPE!! So, I pulled over to the curb (thankfully, there was ample space in this rural community) and proceeded to inspect the source of this noise pollution... It was that darn cat, not the Disney film, the one under the car. It broke off right at the front weld where it meets the downpipes and was being supported solely by the hangers at the rear muffler (for those not aware, the S2 has two silencers, one just behind the cat and the main one).
Hmm... call AAA and wait an hour roofer my own roadside assistance? Duh... I knelt down at the rear and unhooked the hanger from the muffler and pulled the whole thing out the rear. I eyeballed it for a moment... nope, not gonna fit in the car and still be able to close the hatch. Then, it dawned on me... these things came with a tool kit (are you listening, American car manufacturers?). So I pulled mine out and unrolled it. To my relief, I found a 13mm wrench and a pair of pliers, among others).
So, on the side of the road, I wrestled the rusty pliers open and clamped on the 12mm nut withe the wrench on the bolt connecting the cat to the cat-back. It took some effort but I managed to get all three nuts off, threw the pipes in the car and noisily drove back home.
I looked all over the Web for inexpensive replacements... but all were "49-State" legal... and I'm in the 50th State (Peoples Republic of California). I ended up calling Al at PartsHeaven and he had a used one in stock for $300 (new ones are nearly $1,800 no matter where you look). He shipped it and I got it two days later.
Suffice to say, I installed the new parts with new hangers and bushes all around.
I'd like to than the following for their prompt help in this matter:
PartsHeaven, Pelican Parts, TCs Garage and EagleDay.

Karl_W944

Got my sunroof seal set from only944 in the mail today. It was quick and simple removing the 30 year old crusty and rotting piece, but a pain in the butt putting the new one on. Kinda uneven in some spots, but it can be fixed later.

V2Rocket

glad to hear you got it figured out, also glad to hear you found an item at parts heaven that is a reasonable price...that's a rare find.

Magnaflow and Walker exhaust co's have ca-catalyst searches on their websites. the 944 CA universal replacement is about $170, you need to add some pipe length and welding to fit it.

Tiger03447

Yesterday, I dropped the rear suspension, and removed the Torque tube...left the brake cables attached, but cut the flex hoses, which will be replaced, both front and rear...anyway...so now it's on to cleanup under there, and replacement of fuel hoses, brake hoses and anything else that is lurking under there..spiders etc..A bit of washup and then onto undercoat spray to get it all prepped to reassemble..Oh yeah, also pulled the stub shaft and the sideplate off the transaxle to inspect for missing teeth off the R&P.. None found and all intact...minor shavings,& cleaned the magnet. Not much found in the filter paper that I used when I drained the oil. Probably will replace all 3 of the seals..bearing look worn, but will have to wait on the DIMI overhaul ( perhaps it won't need it) fingers crossed...until funds look better....Tiger 03447

HICKS

It does take awhile to make it perfect. It will also sit up a bit high, but over time it will "settle". I've had mine for awhile, and no leaks, or issues.

V2Rocket

I've had my new outer sunroof seal for almost 3.5 years and it hasn't settled flush yet.
But I almost never even open the sunroof.

HICKS

Who's yours made by?

V2Rocket

no idea, it was the OE-replacement from Pelican, whichever mfr they offered in late 2010/early 2011.

Tiger03447

Drove about 2.5 hours down to Hartford, CT and picked up a lot of powdercoated exhaust parts...Ceramic coatings on all the heatshields back by the muffler and up into the TT slot...hangers too, but in black satin...looks GREAT so far...now to put it all back together someday....thanks, Tiger 03447

HICKS

Replaced a cracked ecode with one from Travis @ Rennbay, and ordered a turn signal assembly, mines been acting weird lately.

Karl_W944

20 minutes of cleaning spray, a bucket of water, and an old t-shirt make for some clean and happy wheels.

Chunkerz

Today I FINALLY removed my HVAC box!!!! It took over a year, but I finally got around to getting this bastard out so I can replace the foam seals.

First I removed the blower motor and its related parts



Then I drained my heater core


It's out!


Nice and yucky in there


The after math


Then I took it apart so I could get to all the little flaps. This should be fun to put back together...

Tiger03447

I hope that you took a lot of pictures along the way so when you put it back together next month you can remember better where all the little doo-lollies go..What a monster unit! I'm sure that it will perform quite well when it gets back into the car...the heater core looks good..was it leaking? Good luck with that project! Wowzers!

Tiger03447

I brazed up a screw hole in the top of my gas tank.. some PO decided to mount something to the rear floor with a sheet metal screw..and..put it right through the top of the tank....wonder if he smelled some gas fumes....? some people's children really amaze me....LOL!

Chunkerz

I took a few pictures, but I have a feeling it's still going to be a pain to put back together. Taking it apart was pretty awful and usually taking things apart is the easy part... The heater core is in good condition and not leaking, but the foam around it is completely rotten.

While I have this apart now is a good opportunity to remove the evaporator/expansion valve if I want to delete everything A/C related. I really don't feel like fixing it, but having air conditioning is nice when it's 90 degrees with 70% humidity. I've lived through 3 summers with no A/C, but I have a feeling once I remove it I'll need it. Decisions, decisions.....