unclejosh

The following is a DIY Muffler Install for the 997. Very similar to the 996, but details might not be obvious or posted. Here I will key off what is known already about the 996, and will assume reasonable shade tree mechanic ability.

First, I refer to the fine threads:

Removal of the rear bumper cover and muffler:

http://www.renntech.org/forums/index...howtopic=16935

996 sport exhaust and bypass pipe install:

http://www.renntech.org/forums/index......p=6&#entry6


Here are some items to consider and watch out for:

1) Find a safe stable way to jack up the car with fail-safe in case of jack failure.
2) Remove rear wheels - it is alot easier to remove and install the mufflers with them off
3) Remove rear bumper cover - Remove rear tail lights to access a lone hidden torx screw and see 1 torx in wheel well, in addition to the other obvious screws under the engine lid and under the car - it is alot easier to remove and install the mufflers with the cover off
4) Remove heat shields to access the mufflers - see my pics below, the fasteners are very obvious
5) To remove and re-install new mufflers, follow the above threads......
6) I used WD-40 soak on muffler fasteners prior to removal and fused aluminum anti-seize compond to lube up muffler joints for install.
7) I found that a ratchet with a pivoting head and just the socket was more useful and easier than a ratchet a universal joint and extension and socket.

Here are some pictures which may help:

Torx behind tail light for bumper cover removal:

http://img517.imageshack.us/my.php?i...ghtforrwl7.jpg


Torx in wheel well for bumper cover removal:

http://img71.imageshack.us/my.php?im...wellfortp6.jpg

Exhaust shield that needs to be removed:

http://img508.imageshack.us/my.php?i...inplacees0.jpg

Exhaust shield after removal:

http://img71.imageshack.us/my.php?im...mufflercx7.jpg

Hope this is useful

UJ

summoboy

looks like you have the same pic for "torx behind tail light" and "torx in wheel well".

unclejosh

Correct link is in there now.

UJ

Gert

I've installed dozens of exhausts on the 997 and I never removed the rear bumper.
Just the 3 x M8 nuts on each side that attach the muffler-bracket to the holder and the pipe clamps.
One torx screw on each far/lower side of the bumper to get a bit more clearance when dropping the exhaust.

unclejosh

Gert-

I am referring to the bumper cover, not the bumper - I guessing you are too.

I dont have access to a lift, so I removed those extraneous pieces so I could see better and have slightly more room to wrench- it helped me - I am just a novice.

As you likely know very well, the cover comes off in about 5 minutes max, if you are quick with a screwdriver. I took advantage of the cover removal and cleaned those previously unaccessable areas.

Thanks for your comment, and you have a very cool avatar!

Gert

I was referring to the bumper cover.
I do however use a lift but I am sure it applies to a car on jack stands.

gota911

I have removed/installed the mufflers on my 996 three different times using jack stands and I never needed to remove the bumper cover. I did, however, remove the wheels.