Matt H

Since some German sadist put the exhaust together on these cars I come to my buddies for help. Here is the problem. I am dropping the motor (87 951) and to remove the starter a number of heat shields need to be removed. One of which cannot be removed without the removal of the southern portion of the header. This thing has two triangular shaped areas held togther by 6 bolts (3 or 4 of which can be relatively easily removed). My question is....how in the hell do you remove the ones that are almost touching each other?????? All I have left is to remove the exhaust so I can drop the starter and undo the bellhousing. Anyone in the DFW area who wants to help me remove these bolts is welcome to come by at any time. After about 1 hour, I got a little pissy so I just walked away. I am going to give it another shot tonight if I get and answer here.
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scular

It's called "Get out the sawz-all." I spent a good 12hours removing the exhaust on my turbo. It seemed like every bolt, nut, and thread was striped, welded,rounded off, rusted solid or some other way mangled. From that one experience, I will never remove the stock exhaust system again without hacking it then welding it back or replacing altogether.


Scular

Matt H

All the bolts are moving just fine BUT, you have to have something holding the top bolt while you turn the nut on bottom. the PO just had some new exhaust sections done and I am pretty sure that is why it has been so easy to remove. Since I dont weld, I would rather not cut it off.
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944S2IFISH2

IIRC use a 13mm stubby box wrench to hold the top side and extensions to come up at the bottom side... (Worked on an '86 951)

Lousailor

It's easier if you have another set of hands that can hold the top wrench. I was able to wedge a box wrench against the firewall or engine so that I could unscrew the bolt from below.

sm

FYI, the starter heat shield has "slotted" holes that allow you to slide it away from the two 17mm bolts. So just remove the couple of nuts on the rear of the starter and loosen the two 17mm bolts on the bellhousing and then slide the heat shield towards the back of the car...

Matt H

When you back out the 17mm bolts they hit the exhaust pipe and wont turn any further. I will have my wife hold the top one I guess.
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Waterguy

I bought a set of stubby combo wrenches, a stubby 3/8" drive ratchet with a flex hanle and some wobble extensions. Those bolt were a mild PITA, but not too bad. Lots of penetrating oil!

Matt H

Off to my favorite mall store "sears" it is scary how much I owe them, really it is. BTW, my bolts are 12mm and not 13. Waterguy, these are coming off just fine. My problem was getting to them not unscrewing them, fat hands you see.
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Kevin Baker

Matt, I think they are 13's but, yeah, you need a second set of hands to hold the wrench up top, while you turn below. That's why I keep the children. They can actually be helpfull now and then. "Boy, get me THAT wrench, right there!"

Matt H

My wife is good for holding wrenches, I even have a few t-shirts I got her for it. I thought 13s too but I swear to you, I have removed 2 of them and they really are 12s. Maybe the PO changed them but it doesnt look like it. Maybe he changed 2 and that why I was having such a problem with the others (I know the nuts were 12s but maybe the bolt head is a 13 since you cant see it!)
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Sam Lin

Matt, I'm with you about Sears - I hate totalling up the money I've spent there, it's wayyyyyyy up there. The upside is that they really don't ask questions and will replace anything I break, and I can do that at any store anywhere.

Sam

Matt H

Good thing they are close to my house. They have replaced god knows how many screw drivers! Did you pry with that?? NOPE!
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sm

If we're talking about the same 17mm bolts, they only need to be loosened, not completely removed. Once loosened, and the nuts on the back of the starter removed, you can slide the heat shield off. The heat shield actually has slots at the edge to receive the 17mm bolts, not holes that necessitate removing the whole bolt.

Matt H

Well that might explain a lot. The exhaust still needs to come off, but it can come off further down I suppose. I will give it a look later tonight. Thanks.
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