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Exhaust Issues

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Taunton Andy

New member
Hi
I'm new to the forum and recently acquired my first Boxster so I hope you'll treat me gently! I've noticed my exhaust sounds like it's blowing so popped into ATS today to get some advice. It appears the exhaust mounts, the joint behind the heat deflectors and possibly manifold gasket all need replacing (I think this is what they said). ATS advise main dealer however another local tyre/exhaust garage estimate circa £300 to make good. Any advice on where and how much I can expect to pay. I'm aware this is a common fault with Boxsters. I live in Somerset and to the best of my knowledge have no Porsche specialists in the County. Any advice would be greatly appreciated.

Thanks

Andy
 
I replaced my manifold gaskets when i changed to stainless. Every bolt broke 4 were broken by garage after they said they could do it easy, i ended up having to grind all the broken bolts flush centre drill then using cobalt drill bits drilling them out starting at 0.5mm and going up 1mm everytime till hole was big enought to tap and helicoil and then ss bolts..jobs a pita but i enjoyed the challenge tho..for 300 quid would i trust ats its not a hard job but you have to be very precise when drilling and porsche specialist or service centre will have done it before. I'm not saying anything bad about ats but the garage i went to are great and years of experience and they gave up after an easyout snapped
 
Hi - not sure the age of your car, but if it's a 987 then it's very common for the bolts between the manifold and cat to fail. They are very difficult to remove as they are pressed into the flange. I would think that 3hrs labour is about right to replace (so £300 is a little strong). Replacing the original bolts with stainless is also a good idea.
Hope this helps.
Kind Regards Lee Jones
 
If it's a 986, then the cat to manifold flange bolts are a little easier as there is more access.
I would not replace the manifold to head bolts unless absolutely necessary. As mentioned, these are seized / small / break easily.
kr Lee
 
Taunton Andy said:
Hi
I'm new to the forum and recently acquired my first Boxster so I hope you'll treat me gently! I've noticed my exhaust sounds like it's blowing so popped into ATS today to get some advice. It appears the exhaust mounts, the joint behind the heat deflectors and possibly manifold gasket all need replacing (I think this is what they said). ATS advise main dealer however another local tyre/exhaust garage estimate circa £300 to make good. Any advice on where and how much I can expect to pay. I'm aware this is a common fault with Boxsters. I live in Somerset and to the best of my knowledge have no Porsche specialists in the County. Any advice would be greatly appreciated.

Thanks

Andy
Click to expand...



Lee at Cotswold Porsche isn't a million miles from you.
 
Hi. You don't say how old your Boxster is. However if you got corrosion problems on your exhaust I'm guessing its 10 years plus. I've just spent 3 days replacing the cats on my 2003 986. Most of the bolts were corroded especially those on the manifold to cat union. There is restrictive space, fortunately as I was replacing the cats I could afford the luxury of cutting the tail pipe of the cats at both ends enabling me better access to the flanges, the corroded bolts were then ground away and the remaining stump of the studs heated and unscrewed with large mole grips. The removal took two and a half days. Installation of the new cats 2 hours. Frankly £300 sounds reasonable. Porsche quote was over £2K by the way.
 
Just picking up on this thread, I have this issue with a 2.7 boxster 2007 model. My local garage wont touch them unless I agree that the manifold may need removing and possibly replacing. Looking at the exploded parts diagrams, it appears that there is a bolt with locknut on the end, is it the bolt that is pressed in to the flange? Not a stud? If so, is it possible to drill it out in situ?

The joint failed on the motorway and I ended up being recovered as I wasn't sure what the noise was. I am contemplating trying to sort this myself as my local garage doesnt seem to want to and I am stuck with the car not driveable.
 
Hi keithleam,
It is possible to replace the bolts in situ'. The access is restricted, although the n/s offers slightly easier access. I certainly wouldn't consider removing the manifold. I suspect your garage is suggesting manifold removal as this will enable them to access the cat to manifold joint unhindered, however the if these bolts break which they almost certainly will the cost will go up rapidly. Removing the bolts from the cat/manifold union is challenging. The manifold side is threaded and locking nuts affixed, therefore the heads on the cat side have to be ground away. Removing the 2 diagonal braces and reinforcement plate exposes the 2 lower bolts sufficiently to allow grinding, however the upper bolts are the problem ones. There is no quick fix but from experience a brand new 12" metal file and/or a small engraver "Drabble" with a number of carbide discs would be my "tools of choice". As I said earlier this is no quick fix. However an hour of patience should see the head of the bolt flush with the union. Once all three bolts are flush, uncouple the other end of the cat, and using a sharp chisel separate the two triangular union plates. The remaining studs can then be heated and removed with a decent pair of mole grips.
When replacing with stainless steel bolts, invert the top bolt on the o/s union to avoid fowling the gearbox housing. Don't forget the gaskets!
Good luck.

Mickybarb
 
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