ridebuy

I’ve got a high mileage (over 100k) 997.1 Carrera S manual. I’ll be replacing the muffler soon with Fister sport exhaust and wanted advice on recommended maintenance items I should do while they are removed. Appreciate any help I can get. Thanks.

Patunia

Probably going to have to install new gaskets. Depending on the corrosion, various bolts/clamps.

BillB128

If you're close to replacing your spark plugs, having the side mufflers off makes the job easier.

Also, if you're doing the job yourself, try soaking the bolts with a penetrating oil (especially the bolts connecting the cats to the exhaust).
With that said, given the age of your vehicle, you might be better off cutting off the cat bolts, hammering out the pressed
studs, and replacing them with new hardware. There are a number of threads regarding the procedure.

Hope this helps,
Bill

Petza914

Fabspeed makes the best exhaust gaskets and I keep a couple sets in the parts cabinet in case I have to separate an exhaust joint or pull a header for some reason.

While the exhaust is off, it's easier to do plugs and coils and variocam solenoids which are all in that same area. If a 997.1 and 50k or more miles on the current water pump, id change that, the thermostat, and serpentine belt and idler rollers too.

At over 100k miles if a 997.1 you should also replace all 3 chain tensioners - bank 1 and IMS tensioners are easy - Bank 2 requires removal of the AC compressor and while you have that off, it's a good time to replace your AOS. You need a cam lock tool and crank pulley lock tool to do this as well as new sacrificial plastic plugs for the cam lock plugs.

I just did all of this on my wife's 997 in December at 113k miles. It's a fair amount of work - think it took me 16 hours or so.

ATX_Native

Spark Plugs, did them when I was in there.

ridebuy

Thank you all. Great feedback and advice. I've ordered OEM plugs and ignition coils (just in case), plus a few extra exhaust gaskets.

I think I'll get to the waterpump and thermostat on the next round.

CarreraAlex

I would also recommend replacing the car side bracket that holds the muffler on - these are prone to corrosion on the bottom (#17,18), as well as the bushings (#22) and bolts inside the muffler side bracket (#24,25) you can reuse the side bracket (#23,28)

Just did this myself and had to cut off the bolts on the bracket as the bushings seized the bolt

maiko

Replace the sleeve clamps with new genuine Porsche units. YMMV, but any time I’ve tried to re use clamps (or use new non-Porsche clamps), the sleeves leaked.

carguy999

I am actually doing this soon, replacing muffler - going to put a parts list together for miscellaneous stuff needed like flanges or clamps or whatever and report back.

Anyone know what the difference is in versions here? This is for the first thing mentioned, 17 and 18 in above diagram.


Is it this? and these are almost $300 per side??
https://www.sunsetporscheparts.com/o...rt-99611112762

OK - anyone care to fact check this? Putting this together so the next guy doesn't have to go digging:Supports:

996 111 127 60 or 61

996 111 128 57 or 58



Bushings (x8) - 996 111 229 01



Bolts and nuts for side bracket

Bolts (2 of each) - 900 378 183 09, 900 378 105 09

Nuts (x4) - 900 380 005 09



Sleeve (2 of each) - 900 378 055 09, 997 111 520 00



gasket (x2) and nut (x6), and bolt (x6) - 997 111 113 00, 999 084 046 02, 900 075 365 02

carguy999

Also - my car has a muffler delete right now with a Fabspeed X pipe - is there anything else needed to add back in mufflers?

carguy999

Bumping in case anyone has anything to add

ftc3

I had my exhaust off last year and went through everything before I put it all back together.

I had the whole thing ceramic coated to make sure it never corrodes again. mufflers, clamps, brackets, spark plug coil shields

I replaced every nut and bolt and used copper anti seize. For the exhaust clamps, i purchased stainless steel carriage bolts and nuts. For the headers, I used ARP stainless bolts 771-1001. All other hardware was factory. A year later and it all still looks new.

ronvanr

When replacing the bolts and nuts, what type did you use, zinc plated, stainless, galvanized? - what type works best for muffler applications.

ftc3

For the exhaust clamps, I used a T304 SS M8 x 1.25 x 25mm for the carriage bolt and flange nut. They still look new after a year.

For the rest of the exhaust, I used new factory hardware.

Body In White

I did something similar, but passivated the stainless exhaust to keep it from oxidizing and used titanium hardware when putting it all back together.