Gareth_W Posted May 4, 2021 Report Share Posted May 4, 2021 Hi all, I've just ordered a Top Gear valved exhaust and the biggest issue I'm going to have is removing the original exhaust, can anyone offer any advice on how to remove existing studs, here's a pic of the studs As you can see they are heavily corroded so not sure the best way to tackle them. Gareth. Quote Link to comment Share on other sites More sharing options...
BBB Posted May 4, 2021 Report Share Posted May 4, 2021 I can only offer sympathy. I’ve just done this exhaust install and I was so lucky as mine were in perfect condition and all loosened without drama. The only solace I can give you is that on my 2005 987.1 3.2, the bolts were just straight through, not pressed in. As you don’t need anything from the silencer side of that joint, as you’ll be replacing it all, I would be tempted to angle grind the old pipe off, then with better access you can grind off each nut and hopefully drive the bolts out with a hammer and punch. Good luck! Quote Link to comment Share on other sites More sharing options...
Boxob Posted May 4, 2021 Report Share Posted May 4, 2021 (edited) On my 986 a leak developed at that joint. When I inspected, the nut and bolt (head) had rusted away. The joint was being held together only by the stems of the bolts which had corroded in place. I was able to squeeze the joint together with mole grips, then prise it apart using a screw driver between the flanges. After repeatedly doing this I was able to get more and more movement in the joint until it came apart. I then used a hammer and punch to drive out the bolt stem from the half of the flange it was still stuck in. Based on my experience, I'd grind off what remains of the nut and bolt head and work on the joint as I did. Edited May 4, 2021 by Boxob Quote Link to comment Share on other sites More sharing options...
Gareth_W Posted May 4, 2021 Author Report Share Posted May 4, 2021 @BBB I have considered cutting it off at the pipe but don't really want to do it incase I don't like the top gear unit and have to put original back on, I can only hope that the studs are not pressed, were your studs original or had they been previously replaced? Quote Link to comment Share on other sites More sharing options...
Gareth_W Posted May 4, 2021 Author Report Share Posted May 4, 2021 @Boxob I do think that grinding away what remains of the nuts is best approach, looking at them I maybe able to just prize them off and then work on getting the studs out of the flange. Quote Link to comment Share on other sites More sharing options...
Deano37 Posted May 4, 2021 Report Share Posted May 4, 2021 I feel your pain. Just had to do this last week and mine looked the same. They were spot welded on the stud and nut. Lots of heat and persistence persuaded them to eventually give up. Hammer and punch also needed to get the stud out of a couple of them. The plan was to fit a valves exhaust but not yet done it due to other work needing doing. Good luck. It will be worth it in the end 👍🏻 Quote Link to comment Share on other sites More sharing options...
Laney456 Posted May 4, 2021 Report Share Posted May 4, 2021 Are any of you guys selling your original silencers ? I'm desperate for exhausts from a 3.2S to send to Carnewal Tom Quote Link to comment Share on other sites More sharing options...
Laney456 Posted May 4, 2021 Report Share Posted May 4, 2021 I'm also in exactly the same place... although my exhaust bolts were so rusty the whole joint was completely loose and detached... the studs remain in the catalyst flange ... buggers Quote Link to comment Share on other sites More sharing options...
Gareth_W Posted May 4, 2021 Author Report Share Posted May 4, 2021 @Laney456 Hi Tom, unfortunately the current system is useless as there a hole in the top corner of the muffler (reason for changing it), I only referenced the possibility of reattaching it if i really didn't get on with the top gear unit but then I'd have to try and repair it (unlikely). Quote Link to comment Share on other sites More sharing options...
Laney456 Posted May 4, 2021 Report Share Posted May 4, 2021 Aaaa bugger.... flipping heck Quote Link to comment Share on other sites More sharing options...
Laney456 Posted May 4, 2021 Report Share Posted May 4, 2021 Makes my little cracks looks miniscule Quote Link to comment Share on other sites More sharing options...
BBB Posted May 4, 2021 Report Share Posted May 4, 2021 5 minutes ago, Laney456 said: Makes my little crack look miniscule Quotable, just for comedy value 😂 4 Quote Link to comment Share on other sites More sharing options...
Gareth_W Posted May 4, 2021 Author Report Share Posted May 4, 2021 2 minutes ago, BBB said: Quotable, just for comedy value 😂 Damn beat me to it, I was going to go along the line of "bet she wouldn't say that" 😂 Quote Link to comment Share on other sites More sharing options...
Laney456 Posted May 4, 2021 Report Share Posted May 4, 2021 Me and my miniscule crack 🤣🤣 Quote Link to comment Share on other sites More sharing options...
andygo Posted May 4, 2021 Report Share Posted May 4, 2021 55 minutes ago, Laney456 said: Me and my miniscule crack 🤣🤣 Yeah, but what size are your nuts? Quote Link to comment Share on other sites More sharing options...
Laney456 Posted May 4, 2021 Report Share Posted May 4, 2021 5 minutes ago, andygo said: Yeah, but what size are your nuts? Massive nuts because I can't get my bolts to fit.... I'll get my coat. 🙂 Quote Link to comment Share on other sites More sharing options...
Laney456 Posted May 4, 2021 Report Share Posted May 4, 2021 PS.. my cracks.. Incidentally... do you think these are repairable / patchable ? Flipping exhaust is driving me nuts 🙂 Quote Link to comment Share on other sites More sharing options...
iborguk Posted May 4, 2021 Report Share Posted May 4, 2021 2 minutes ago, Laney456 said: PS.. my cracks.. Incidentally... do you think these are repairable / patchable ? Flipping exhaust is driving me nuts 🙂 Had similar on a 987.1 exhaust - not repairable, had that feedback from both Gert (Carnewal) and a rated local welding guy. Quote Link to comment Share on other sites More sharing options...
Laney456 Posted May 4, 2021 Report Share Posted May 4, 2021 1 minute ago, iborguk said: Had similar on a 987.1 exhaust - not repairable, had that feedback from both Gert (Carnewal) and a rated local welding guy. 🥵 FFFFF Quote Link to comment Share on other sites More sharing options...
iborguk Posted May 4, 2021 Report Share Posted May 4, 2021 16 minutes ago, Laney456 said: 🥵 FFFFF Ad could do with better pics but might be worth a follow up https://www.ebay.co.uk/itm/284281330639?_trkparms=aid%3D111001%26algo%3DREC.SEED%26ao%3D1%26asc%3D20160908105057%26meid%3Da40cd9826e134a3c8e4b36492f32145c%26pid%3D100675%26rk%3D1%26rkt%3D15%26mehot%3Dnone%26sd%3D284281330639%26itm%3D284281330639%26pmt%3D0%26noa%3D1%26pg%3D2380057%26brand%3DPorsche&_trksid=p2380057.c100675.m4236&_trkparms=pageci%3A0d061045-ad1d-11eb-9f6b-c257e0e92873|parentrq%3A393721001790a499ce8b0cc1fffe5f38|iid%3A1 Quote Link to comment Share on other sites More sharing options...
Boxstercol Posted May 5, 2021 Report Share Posted May 5, 2021 My exhaust studs / nuts, or what’s left of them, look the same but thankfully no signs of any blowing from the join. If extracting using a hammer / punch, be prepared to change the lambda probe as I’ve read numerous posts about these failing after the exhaust has been tackled. Apparently they don’t like the shock of the repeated hammering... Quote Link to comment Share on other sites More sharing options...
Gareth_W Posted May 5, 2021 Author Report Share Posted May 5, 2021 (edited) 44 minutes ago, Boxstercol said: My exhaust studs / nuts, or what’s left of them, look the same but thankfully no signs of any blowing from the join. If extracting using a hammer / punch, be prepared to change the lambda probe as I’ve read numerous posts about these failing after the exhaust has been tackled. Apparently they don’t like the shock of the repeated hammering... Thanks for the tip, if the sensors are prone to fail because of the shock then it might be worth trying to remove them first, although that might be easier said than done. Edited May 5, 2021 by Gareth_W Typo Quote Link to comment Share on other sites More sharing options...
Robster66 Posted May 8, 2021 Report Share Posted May 8, 2021 Wouldn’t there be a code if the sensors fail? Speaking as someone who’s had the studs replaced a year ago.... Quote Link to comment Share on other sites More sharing options...
Paul P Posted May 8, 2021 Report Share Posted May 8, 2021 If there hasn’t been a problem for a year then I guess you are fine. If the sensors were damaged by the shock from hammer then they would cause issues soon after. Quote Link to comment Share on other sites More sharing options...
entdgc Posted May 9, 2021 Report Share Posted May 9, 2021 @bally4563 did mine for me using his portable acetylene torch kit. Burnt them out in under a minute each one. Brilliant bit of kit which I ever needed wouldn't hesitate to buy. Luckily Mick was only just down the road from me otherwise I would still have been running my (very successful) home made bent washer clamps. Quote Link to comment Share on other sites More sharing options...
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