981 GTS exhaust leak and rusted flange bolts (2016, only 12,500miles)
- Thread starter Andy Barr
- Start date
I’d find an Indy with a lower labour rate and get it fixed, stitch in time etc.
Jono,
This won't be the last reference to this problem on this and other Porsche forums. Typical of cost-cutting measures these days even on the so-called premium makes of car, especially when spec'ing a more durable fastening would cost pence.
The nuts don't look too bad and I'm sure it would be worth trying some penetrating fluid and leaving it for a while to do its work. Just make sure that you use a decent spanner or socket to free them up ... go gently. You should very quickly get a feel for whether or not they're going to free-up.
Jeff
This won't be the last reference to this problem on this and other Porsche forums. Typical of cost-cutting measures these days even on the so-called premium makes of car, especially when spec'ing a more durable fastening would cost pence.
The nuts don't look too bad and I'm sure it would be worth trying some penetrating fluid and leaving it for a while to do its work. Just make sure that you use a decent spanner or socket to free them up ... go gently. You should very quickly get a feel for whether or not they're going to free-up.
Jeff
Thanks all,
any recommendations on sourcing better bolts? Seems worthwhile replacing them with something better given the labour rate - I assume even an indy will have a chunky labour charge if it's fiddly to access.
any recommendations on sourcing better bolts? Seems worthwhile replacing them with something better given the labour rate - I assume even an indy will have a chunky labour charge if it's fiddly to access.
Apologies if I've marked anyone's post as unhelpful, clicked on the "helpful" tag and now showing "unhelpful" - assume it's a toggle but not clear which way I've done it!
Jono,
Have a close look, but a problem could be that I don't think that it's a simple nut and bolt fixing. I've a feeling that the engine-side flange is studded so the studs have to be driven out - maybe from the rear where access is limited? If it's necessary to remove the manifold and cat to get to them you've got more (corroded??) bolts to remove.!
Jeff
Have a close look, but a problem could be that I don't think that it's a simple nut and bolt fixing. I've a feeling that the engine-side flange is studded so the studs have to be driven out - maybe from the rear where access is limited? If it's necessary to remove the manifold and cat to get to them you've got more (corroded??) bolts to remove.!
Jeff
Jeff,
You are correct - well spotted! When I replaced my OEM manifolds I noticed they had studs for connecting to the over-axle pipe. I had them drilled out and still have the manifolds in my garage awaiting someone who wants them.
You are correct - well spotted! When I replaced my OEM manifolds I noticed they had studs for connecting to the over-axle pipe. I had them drilled out and still have the manifolds in my garage awaiting someone who wants them.
Hi, been a member for a while but first post on here I think. Took my 981 GTS to Hull OPC on Thursday for "major service" (aka spark plugs and oil), and the health check showed that the exhaust flange bolts were rusty and required replacement (at a cost of £660...). They just said it was advisory, but didn't explain that the right hand side exhaust flange (I think it's the connection at rear of CAT) actually had a small leak, until I went to collect the car at the end of the day.
They didn't try nipping it up, as if the nuts rounded or bolt snapped they would have had to replace at the above cost. The senior technician said it was up to me, was noted on MOT but only very small leak, and not serious otherwise the engine mgt light would come on. I'm debating on the best course of action, I have a friendly and reliable non-specialist local garage that I could try, while I'm aware it's a fiddly job with awkward access (i.e. on a Porsche
), the OPC cost seems astronomical for four bolts. I've had a quick look at design911 but couldn't find the bolts on there.
Seems a simple job for most garages but not sure if I'm missing something, and would be better sticking to specialist / OPC. any thoughts / experience appreciated.
I have an extended Porsche warranty but as expected not covered.
I'm debating trying to nip it up myself after dousing the nut in penetrating fluid?
Thanks all
Jono
They didn't try nipping it up, as if the nuts rounded or bolt snapped they would have had to replace at the above cost. The senior technician said it was up to me, was noted on MOT but only very small leak, and not serious otherwise the engine mgt light would come on. I'm debating on the best course of action, I have a friendly and reliable non-specialist local garage that I could try, while I'm aware it's a fiddly job with awkward access (i.e. on a Porsche
), the OPC cost seems astronomical for four bolts. I've had a quick look at design911 but couldn't find the bolts on there. Seems a simple job for most garages but not sure if I'm missing something, and would be better sticking to specialist / OPC. any thoughts / experience appreciated.
I have an extended Porsche warranty but as expected not covered.
I'm debating trying to nip it up myself after dousing the nut in penetrating fluid?
Thanks all
Jono
No points to the Porsche exhaust system designer there Ralph! Clearly they weren't thinking about maintenance accessibility, but then a stud and nut is a simple single-tool assembly operation compared with a nut and bolt. Of course, if the stud had been on the other flange disassembly would have been much simpler.
So a 5-minute job becomes 4-hours at PC rates = £660. []
Jeff
So a 5-minute job becomes 4-hours at PC rates = £660. [
]Jeff
Thanks Jeff, I think you are right, the flat round head on the stud suggests this is the case. I assume OPC would replace with a nut/bolt.
AndrewCS
Active member
… there`s a gasket in there , probably corroded hence the `blow`.
https://nemigaparts.com/c...orsche/981c/40/202000/
https://nemigaparts.com/c...orsche/981c/40/202000/
Hi,
There was a bit of a debate in the
Boxster forum https://www.porscheclubgb.com/forum/tm.aspx?m=409165
I THINK the consensus was brass (on steel) or phosphor bronze.
The original steel certainly want replacing.
There was a bit of a debate in the
Boxster forum https://www.porscheclubgb.com/forum/tm.aspx?m=409165
I THINK the consensus was brass (on steel) or phosphor bronze.
The original steel certainly want replacing.
That schematic is really useful, thanks.
Had a read through the other thread, sounds a really fun job as well as a common problem. Saw something on 911uk which suggests it’s not limited to the cayman/boxsters either
Had a read through the other thread, sounds a really fun job as well as a common problem. Saw something on 911uk which suggests it’s not limited to the cayman/boxsters either
AndrewCS
Active member
Water sitting in the joint where the gasket is, combined with low usage is a contributing factor to your `blow`.
FYI …
https://www.greasemonkeydirect.com/collections/exhaust-manifold-nuts-studs
https://www.westfieldfasteners.co.uk/Nut_M.html
BZP Stover Nuts - An elliptical offset type hexagon locking nut. Of all metal construction, and can be reused indefinitely. A locking nut for use in higher temperatures where a locking nylon ring nut would be unsuitable.
FYI …
https://www.greasemonkeydirect.com/collections/exhaust-manifold-nuts-studs
https://www.westfieldfasteners.co.uk/Nut_M.html
BZP Stover Nuts - An elliptical offset type hexagon locking nut. Of all metal construction, and can be reused indefinitely. A locking nut for use in higher temperatures where a locking nylon ring nut would be unsuitable.
My wife's 981 Boxster had similar, local garage drilled out & replaced for £150 from memory. Will take my 981 GTS Cayman to him to do too. IT is great when you find a good local person without OPC labour rates. Oh and one that tries to mend vs simply replace which OPC wanted to do for a PDK oil sweat, free fix locally vs £800 replace attitude from OPC.
GordonT said:
Near Bracknell. I went to an independent exhaust & tyre company to ask them if they did this sort of stuff & they pointed me in this garages direction. He does loads of Porsche exhausts & is amazed at the cheap bolts given how good the rest of the car is quality wise. I was amazed at it happening on a 4yr old low mileage car.
Worth trying similar for anyone in the same situation.
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