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Hello!
I have my 997.1 S, relatively stock with the exception of the FABSPEED carbon intake system. However, apparently there was some previous issues with the connection pipes from the Cat to the muffler. Previous owner did bad repairs (gunked it up with sealing tape and whatever else) and now there is a slight exhaust leak from the connectors, its not bad above 1.5K RPM but below that, its just a slight airy noise and not sure if im losing any backpressure because of it. Picture below for reference.
Now, WITHOUT upgrading and spending 1.2K+ on new cats/x pipe, what are my options? Can I remove the cats only and see if I can clean it up and buy new connectors? How hard is it (possible) to remove the cats only?
What I am thinking:
1) Take it to an exhaust/muffler shop and see what they say (clean it up, re-attach and possibly weld them together?) Risking a costly quote ?
2) Take it off myself (possible to remove cats only?), inspect, buy new connectors and hopefully re-connect, re-install
3) I'm open to purchasing a direct replacement (oem or aftermarket) high flow cat or oem and installing (used as well! if you have any)
4) Cut my losses and just upgrade to an awesome X pipe w/cats
Help please! Its starting to get on my nerves and seems like a simple enough fix that a shop can either say, fixed it, cheap and fast or quote me 2K + for replacement and install lol
thank you rennlist
Is that a photo of a 997? That picture is interesting as it has X51 headers from an S car, but base 3.6L exhaust tips...unless, maybe it's from a 996.
Anyway,. if the areas in question are the two blue rectangular boxes, you can probably source a better clamping sleeve for those junctions. You'll need to measure the outside diameter of the pipes where they mate their (digital caliper) then source an exhaust sleeve that includes a sealing membrane that goes outside the pipe junction but inside the new clamping sleeve. These sealing membranes are made of asbestos or a similar material that withstands the high-heat applications. A company like DEI might have something for you since they do turbo blankets, exhaust wraps, fire-sleeve kits for hoses, etc.
It's also possible that someone over-tightened the clamps currently on those junctions which may have puckered the slip fit end of the inner pipes which won't let the outer pipe slip on and seal up well... or didn't get everything lined up before doing the final tightening on the existing clamps.
I think your first step is to loosen all the bolts EXCEPT the header ones, remove the slip fit clamps in the blue rectangles and see if you can move things around a bit to achieve better alignment or that may reveal why the pipes don't slip fit together well. If the pipes are out of round, a muffler shop may be able to re-round them with some type of mandrel tool.
I can't give you a single best resolution recommendation until we better understand the actual cause of the leak.
Here is what I would do..... and honestly, I have no clue if this would work. Seriously.
First, I would buy a case of Pilsner Urquells... chill. Then I would put the backend up on jack stands, remove the rear bumper and side skirts.. then loosen all the bolts on the muffler (but leave the three bolts on the cats intact.. don't touch these evil things. Then I would work to re-position the muffler to make the angle between those two pipes more in line with each other. Then re-tighten it all up.
I know from removing the side mufflers for three plug changes and from installing the Sharkwerks pipe, that the bolts all allow for play. So my first instinct is to re-align everything. Sounds like someone installed the system by tightening down each bolt and was left with something out of alignment. At minimum, having it all apart... or loosened up ... will present you with a solution.
So you can obviously see black soot where the leak is......did you try tightening the nuts? Is it really a problem? If anything it will be a little louder. Just keep the rpms above 1500. Sorry I couldn't resist
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997 S Cat/Muffler Leak - please help!
