Header installation - Need Help!

[kt1]

On the passenger side flange where there are 3 nuts: The top nut is actually welded to a mount of sort and a bolt on the other side. while the two bottom nuts are just nuts screwed onto studs that are connected to the flange.


You must basically get a 13mm regular wrench, hold that nut in place, then get a ratchet (or a small 3/8 in drive impact gun which i used to take off all bolts so as to prevent stripping or breaking bolts) with about a 6-9 in extension with a 13 mm socket and fit it through the lower bar of the suspension and unbolt from there.

I used an impact gun with a 3 inch deep socket 13mm connected to a 3 inch extension and hit it from the rear where the bolt is.

As for the broken stud, I wouldn't recommend those easy-out or drilling, because you run risk of hitting the threads of the hole into the cylinder head. Especiallg given the clearance and angels if you're working under jackstands, It's not very safe.

A bolt actually broke off when i was screwing it in after I installed my headers. So right now I have an exhaust leak from that one bolt not there. I am going to go to a shop to have them weld a nut (they weld the nut through the hole in the middle) to the broken stud and then you can use that welded on nut to unwrench the fabricated bolt out.


I can snap some pics of it tommorow to better illustrate what i am saying.

[dcporsche99]

"So is this one stuck or did it snap?"

The one on the passenger's side appears inaccessable, but still intact.

[dcporsche99]

"On the passenger side flange where there are 3 nuts: The top nut is actually welded to a mount of sort and a bolt on the other side. while the two bottom nuts are just nuts screwed onto studs that are connected to the flange.

You must basically get a 13mm regular wrench, hold that nut in place, then get a ratchet (or a small 3/8 in drive impact gun which i used to take off all bolts so as to prevent stripping or breaking bolts) with about a 6-9 in extension with a 13 mm socket and fit it through the lower bar of the suspension and unbolt from there.

I used an impact gun with a 3 inch deep socket 13mm connected to a 3 inch extension and hit it from the rear where the bolt is.

As for the broken stud, I wouldn't recommend those easy-out or drilling, because you run risk of hitting the threads of the hole into the cylinder head. Especiallg given the clearance and angels if you're working under jackstands, It's not very safe.

A bolt actually broke off when i was screwing it in after I installed my headers. So right now I have an exhaust leak from that one bolt not there. I am going to go to a shop to have them weld a nut (they weld the nut through the hole in the middle) to the broken stud and then you can use that welded on nut to unwrench the fabricated bolt out.


I can snap some pics of it tommorow to better illustrate what i am saying."



Thanks for the reply and good pointers. As soon as I can get that one little guy out and replace the old with the new header on that side I will get it to a local shop to get that taken care of....yes, please post some pics. I would really appreciate it. I will have to get some good pics with a digital camera so I can post them up as well.

[dcporsche99]

"You must basically get a 13mm regular wrench, hold that nut in place, then get a ratchet (or a small 3/8 in drive impact gun which i used to take off all bolts so as to prevent stripping or breaking bolts) with about a 6-9 in extension with a 13 mm socket and fit it through the lower bar of the suspension and unbolt from there."

Wow! I don't know why I didn't see the obvious yesterday.........

[dcporsche99]

Hi,
Since my extension is too long...close to a 18" copper pipe (from my basement)...this might be a silly question too, but I'll give it a shot anyway. Can a torque wrench be used as an everyday tool (to loosen and tighten bolts..etc.) or is it just for the last tightening measurement? If I could use this, what setting would I put it on to give me enough "umpf" (if I may use that verbiage) to get this bolt off?......................nevermind, I was able to answer this question myself. Thanks anyway.

[dcporsche99]

"I didnt read all the replys but my suggestion is HEAT and vise grip pliers. The one pic is a stud and you need heat and it will come right out."

Hi Ohio,

I think I'm gonna hold off on this one and leave this to the muffler guys....I'm a bit uneasy with the flame thing, especially with all that flammable stuff under the car. I could easily just see myself in one of those cartoons/comedy scenerios where a stick of dynamite blows up in my face (ie. burned hair on ends and soot and burns all over my face). I still like my face (LOL)...thanks though. Maybe if I were working outside....

[dcporsche99]

That last nut ended up coming out with the help of my new variable speed dremel. Of course, thanks to my brother's pre-holiday present. Thanks Bro! No wonder why he told me to hold off on the header install. It's not a necessary tool to have as part of the installation, however in this case....boy, was it ever handy!

So, I guess the one note that may be helpful would be to first remove the small weld that is located at the top of where the nut and flange actually meet (cat end). Otherwise, it's a bit challenging to get a good hold of it with an open ended 13 mm wrench while using a ratchet (connected to a 13 mm socket )on the other end. I ended up stripping it. (Note: this is a M8 nut & a single M8 mm bolt accd'g to the 1997-2004 Bentley Service Manual. There are no other bolts of this type that have a small weld b/w the flange and the nut located at the cat end on either the driver's or passenger's side on a 1999. The other studs / bolts are heat pressed to the flange).

Also, when putting the headers on (at least these headers), it may be a good idea to get the two end bolts in first, but not too tight. Just so that the gasket lines up well and you have the correct fitment; although just to get a bolt or two in there to hold it up may work just as well. The headers get heavier and fatigue starts to set in when carrying them overhead while lying on your back.

Anyway, that stubborn nut is off and the headers are installed. I still have to make an appointment with my local Porsche mechanic to take care of the leaks from the broken studs and bolts. But, I will have to do that once my header wraps come in so that I don't melt my AC line. Other than that, it was a very cool experience!!

Will post some pics as soon as I can if anyone is interested!! :dance: