Muffler removal - impossible!

[kdh]

Hi all,
I have a 2004 986 S and am trying to remove the muffler.
I have removed the bumper, loosened all the clamps and sleeves on the u-pipes but I can't physically get my hands up to remove the top two nuts which are behind the bolts in the centre of the hanger, which are not even visible.

Is there a trick to this or is there another way of releasing the muffler?

Would loosening the allen key bolts on the silver cylinders work?
Thanks in advance.

[Marc_986]

Multiple ways about it (must say my experience is on the 5 speed and 987 6-speed, not the 986 6-speed).
- Remove the bolts as you indicate
- Remove muffler with the transmission side bracket (unbolt from transmission)
- Undo the two bolts you wanted to from the bottom with a socket and extension.

[78F350]

The two bolts that are circled are locked in place and will not turn. The other side has two recessed nuts that you can remove fairly easily if you know where to put the wrench.

I use a stubby ratchet once it breaks free to make it easier to get some turns.

[kdh]

Thanks for the reply and the pics.

The problem with removing the two bolts from the other side is that I can't get my arm/hand up there and I'm not a big guy.

There is a steel bracket in the way - do some remove this?

I can't believe replacing a muffler could be so difficult. No wonder the mechanics charge so much.

[Starter986]

Originally Posted by kdh

Thanks for the reply and the pics.

The problem with removing the two bolts from the other side is that I can't get my arm/hand up there and I'm not a big guy.

There is a steel bracket in the way - do some remove this?

I can't believe replacing a muffler could be so difficult. No wonder the mechanics charge so much.

I removed my muffler when preparing access for my mechanic to remove my transmission.

If that is a pic of the underside of your car... you've more **************** to remove so you can gain access to those nuts. Patience, patience, patience. Remove the traingle covver... everything that might be in the way of the muffler.

FWIW... that's what I execised because those two nuts can be a ********************. Good luck.

[kdh]

Thanks for the reply.

The silver piece of metal where the red arrow is pointing on my pic, can this be removed or is it holding something important in place?

[Starter986]

Originally Posted by kdh

Thanks for the reply.

The silver piece of metal where the red arrow is pointing on my pic, can this be removed or is it holding something important in place?

It can, and will, be removed. Nothing you have to worry about is attached.

Waiting for the "success" post.

[kdh]

Will the muffler drop down if i ONLY remove the two allen key bolts from each of the silver cylinders?

[78F350]

Originally Posted by kdh

Will the muffler drop down if i ONLY remove the two allen key bolts from each of the silver cylinders?

Since I'm doing Boxster stuff today...

If everything else is clear of the muffler, yes. The allen bolts are threaded on the inside and screw onto studs on the muffler:


I'm still wondering why it is impossible to remove those two nuts. I am of fairly standard proportions, losing some flexibility now over 60 years old, 6' tall, 190lbs, and wear size (L) gloves. On my 2004 S I can reach the nuts without trouble and don't need to remove anything or jack the car up to do it.


I first break the nuts free with a standard 3/8 ratchet and 13mm socket, then remove it with a shorter wrench.



I am exceptional in many ways, but have no skills as a mechanic other than being stubborn and persistent.

[kdh]

Thank you for that info and I appreciate the images, I shall remove the allen key bolts seeing as I can't seem to get to the two nuts on the other side.

I wonder why no-one has ever mentioned this way of removing the muffler, and I must have seen 25 videos and read lots of articles.

I can't even get under the back of the car without jacking it up, let alone reach up to the nuts. ?? Exceptional? You must be!

[kdh]

Thanks for your help guys, exhaust is now off (wahey) thanks to the Stubby Ratchet approach!