Boxster S OEM Muffler removal

[LuisR]

thanks to all for the help provided.

I got another question, i want to remove the exhaust and I want to do it if possible without removing the rear bumper. I know some of you will say that this is easy but I rather not remove it if I don't have to. So I have attached a picture of an OEM muffler with some elliptical and rectangular figures.

I am assuming that to remove the muffler I will need to loosen the bolts enclosed in the elliptical shape and how about what is inside the two squares??? Do i have to unbolt anything there??? or that has no bolts???

Thanks,

[KevinC]

Yes. You need to remove the bolts which attach the hangers and loosen the bolts on the clamps for the "U pipe" so it can be removed. To remove the muffler, you don't need to do anything with the cylinders in your rectangular boxes. However, you may need to transfer those and the cross-bar to your new muffler after you remove the old one.

Your picture raises an interesting question about the muffler R&R. I think most people leave the aluminum piece (shown in the middle of your picture) attached to the car and unbolt the muffler from it. However, you have to remove the top two bolts blindly and that part is challenging. If that aluminum piece can be easily removed, it would make the muffler removal easier.

I left the bumper cover on when I removed the muffler on my 2000 S to install a PSE. That worked OK. However, I was having a hard time re-installing the "U pipes" so I ended up removing the bumper cover for better visibility and access to the clamps. If I had a little more confidence in what I was doing, it would not have been necessary to remove the bumper cover. That said, it IS easy to remove the bumper cover. The only trick is figuring out the reusable "rivets" used to attach the spoiler.

[LuisR]

Yes. You need to remove the bolts which attach the hangers and loosen the bolts on the clamps for the "U pipe" so it can be removed. To remove the muffler, you don't need to do anything with the cylinders in your rectangular boxes. However, you may need to transfer those and the cross-bar to your new muffler after you remove the old one.

Your picture raises an interesting question about the muffler R&R. I think most people leave the aluminum piece (shown in the middle of your picture) attached to the car and unbolt the muffler from it. However, you have to remove the top two bolts blindly and that part is challenging. If that aluminum piece can be easily removed, it would make the muffler removal easier.

I left the bumper cover on when I removed the muffler on my 2000 S to install a PSE. That worked OK. However, I was having a hard time re-installing the "U pipes" so I ended up removing the bumper cover for better visibility and access to the clamps. If I had a little more confidence in what I was doing, it would not have been necessary to remove the bumper cover. That said, it IS easy to remove the bumper cover. The only trick is figuring out the reusable "rivets" used to attach the spoiler.

Thanks,

I am actually going to install the same exhaust back on the car. I just need to remove it so that I can install two by-pass SS tubes to simulate the Tequipment exhaust. See pictures from Germany maker below. I saw this on ebay but I don't want to pay over $1000 for something that can be done here in the states. i already found the tube and a good welder. The kicker here in comparison to other countries is the freaking labor. This guy quoted me 5 hrs to do this work, which equates to $300, plus $120 in material. So total is $420. It is still a lot less than most after market systems. I keep you guys posted with the results.

Edited March 29, 2007 by LuisR

[John V]

thanks to all for the help provided.

I got another question, i want to remove the exhaust and I want to do it if possible without removing the rear bumper. I know some of you will say that this is easy but I rather not remove it if I don't have to. So I have attached a picture of an OEM muffler with some elliptical and rectangular figures.

I am assuming that to remove the muffler I will need to loosen the bolts enclosed in the elliptical shape and how about what is inside the two squares??? Do i have to unbolt anything there??? or that has no bolts???

Thanks,

It is quite easy to do without removing the bumper. Not sure why people remove the bumper.

The "trick" is to remove the two fasteners from the center of that long flexible piece that you have shown attached to the muffler in your picture. You can see them in that pic.

The long flexible piece then can be pushed backwards out of the transmission to muffler mounting plate and the muffler will drop out.