Lots of band aids.

 

We need pics of this special tool. I haven't been able to sleep just thinking about it and how easy it would make my life.

 

On my 99 the 3 bolts you mention are weld studs on the #23 bracket. Did not realize Porsche changed this to bolts. The studs are better.

 

Don't know what it looks like but I think it lives in Texas

 

They are still studs/nuts... Fixed original post.

 

Thanks for the help with tools. I found the same Kobalt Bit Driver set (AKA - Porsche tool) online. I now have all of the parts and tools sitting in my garage ready for the job. Planning to work on it between Christmas and New Years. Cheers!

 

Johnny,
I just put everything back together today...take Pete's advice and put separate your muffler from the bracket and put the bracket back on with the three bolts. Then put the muffler on with the bolts that Pete has highlighted going up from the bottom. It's a bit of a pain to get the muffler back in but this way, if you decide to remove it again it will be easy. I replaced the bolts on the bracket, the muffler clamps and the bolts that Pete highlighted with stainless steel so they won't rust again. If you need any advice, shoot me a PM..not that I'm a great mechanic, but since I just did it, I might be able to help...

 

Thanks. I have new muffler brackets and will wait to see what my bolts look like. This was a southern car until last year and I don't drive on salty PA roads (visual inspection looks good).... But I'll make that call once I have it all apart.

One last question I have after reading your posts. How did you manage to get to that last electrical connector? Now that I have the tool I know how to get to the bolts, but was there a trick for the electrical connector and coil/plug removal? Thanks for all of your help and congratulations on completing you project.

 

I have my mufflers off just waiting for new coil packs to arrive before I can finish the same job. My muffler bolts (24 and 25 in the diagram) are all in rough shape. I was considering changing to stainless for the same reason but after a lot of googling I found that it might not be a great idea. Stainless steel isn't recommended for exhaust bolts because it has a tendency to gall when heated which could make them impossible to separate in the future. It also doesn't have nearly the same tensile strength as high grade steel. Stainless should definitely be avoid for manifold bolts due to the temperature although for the muffler bolts here I highly doubt they get hot enough to be a problem.
A better solution is likely to use stainless bolts with brass nuts to solve the galling problem.

I'm still on the fence and may have to just buy the highly-overpriced Porsche bolts since I can't seem to find the right sized bolts locally. If anyone has bought any of the long (70mm and 140mm) bolts in SS with brass nuts and is willing to share please let me know :-)

 

I used ss nuts and bolts on my 81 911 for cat attachments. I swapped my cat for a by-pass every other year after each smog test. I had no problems with them over the 7 years I did this.

 

Johnny..that last connector is a bear to say the least...but I was able to carefully push the rubber cover up with a screwdriver and then pressed the connector with the same..you can just barely get a finger on each side to slide it back on and make the connection...it's slow and tedious, but it can be done...

kgoertz...yes I read all of the same things about stainless bolts on the exhaust...but the fact of the matter is that if you buy an good aftermarket exhaust (fabspeed, borla, etc) they all come with stainless steel so while it may be an issue, most manufacturers still use it so I'm taking my chances...the worst thing that can happen is that I have to cut the clamps or bolts off if I ever need to replace something...btw...I got my 140 and 70 mm M8 bolts from boltdepot.com in stainless steel..I couldn't find M10 carriage bolts for the exhaust so I ended up just putting in 3/8" which fit fine

 

Interesting. I was trying to find out if the worry about SS bolts was based on evidence or theory. It sounds like it might not be a problem in practice in which case it is worth the upgrade to avoid having the bolts rust to pieces.

 

nymart - I ended up not removing the mufflers. I have a factory sport exhaust system and it has a motorized control assemble connected to the pipes. It looked a little confusing to disconnect so I started on the driver side with just the bumper and heat shield removed. After completing that I moved on to the passenger side. That passenger rear was a real PITA! The Kobalt ratchet bit tool was a life saver!

Thanks for the help!

 

Johnny...glad you were able to complete it...now it's on to the next task or mod!!!

 

Man I did this job with everything in place what a b@$!# plugs coils and do you know I had a misfire on #5 yesterday crazy