Muffler Install for the 997

[unclejosh]

Muffler Install for the 997

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The following is a DIY Muffler Install for the 997. Very similar to the 996, but details might not be obvious or posted. Here I will key off what is known already about the 996, and will assume reasonable shade tree mechanic ability. First, I refer to the fine threads: Removal of the rear bumper cover and muffler: http://www.renntech.org/forums/index.php?showtopic=16935 996 sport exhaust and bypass pipe install: http://www.renntech.org/forums/index.php?s...p=6entry6 Here are some items to

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• Author
  unclejosh
• Category
  Carrera (997-1) - Mods
• Submitted
  12/07/2008 06:33 PM

 

[larrytrk]

The following is a DIY Muffler Install for the 997. Very similar to the 996, but details might not be obvious or posted. Here I will key off what is known already about the 996, and will assume reasonable shade tree mechanic ability.

First, I refer to the fine threads:

Removal of the rear bumper cover and muffler:

http://www.renntech.org/forums/index.php?showtopic=16935

996 sport exhaust and bypass pipe install:

http://www.renntech.org/forums/index.php?s...p=6entry6

Here are some items to consider and watch out for:

1) Find a safe stable way to jack up the car with fail-safe in case of jack failure.

2) Remove rear wheels - it is alot easier to remove and install the mufflers with them off

3) Remove rear bumper cover - Remove rear tail lights to access a lone hidden torx screw and see 1 torx in wheel well, in addition to the other obvious screws under the engine lid and under the car - it is alot easier to remove and install the mufflers with the cover off

4) Remove heat shields to access the mufflers - see my pics below, the fasteners are very obvious

5) To remove and re-install new mufflers, follow the above threads......

6) I used WD-40 soak on muffler fasteners prior to removal and fused aluminum anti-seize compond to lube up muffler joints for install.

7) I found that a ratchet with a pivoting head and just the socket was more useful and easier than a ratchet a universal joint and extension and socket.

Here are some pictures which may help:

Torx behind tail light for bumper cover removal:

Torx in wheel well for bumper cover removal:

Exhaust shield that needs to be removed:

Exhaust shield after removal:

Nice article Josh. What did you install PSE?

[unclejosh]

Hello Larry,

I was fortunate enough to get a deal on a set of Tubis- wow, they sound great, no drone.

Regards,

Josh

The following is a DIY Muffler Install for the 997. Very similar to the 996, but details might not be obvious or posted. Here I will key off what is known already about the 996, and will assume reasonable shade tree mechanic ability.

First, I refer to the fine threads:

Removal of the rear bumper cover and muffler:

http://www.renntech.org/forums/index.php?showtopic=16935

996 sport exhaust and bypass pipe install:

http://www.renntech.org/forums/index.php?s...p=6entry6

Here are some items to consider and watch out for:

1) Find a safe stable way to jack up the car with fail-safe in case of jack failure.

2) Remove rear wheels - it is alot easier to remove and install the mufflers with them off

3) Remove rear bumper cover - Remove rear tail lights to access a lone hidden torx screw and see 1 torx in wheel well, in addition to the other obvious screws under the engine lid and under the car - it is alot easier to remove and install the mufflers with the cover off

4) Remove heat shields to access the mufflers - see my pics below, the fasteners are very obvious

5) To remove and re-install new mufflers, follow the above threads......

6) I used WD-40 soak on muffler fasteners prior to removal and fused aluminum anti-seize compond to lube up muffler joints for install.

7) I found that a ratchet with a pivoting head and just the socket was more useful and easier than a ratchet a universal joint and extension and socket.

Here are some pictures which may help:

Torx behind tail light for bumper cover removal:

Torx in wheel well for bumper cover removal:

Exhaust shield that needs to be removed:

Exhaust shield after removal:

Nice article Josh. What did you install PSE?

[rmasu]

Hi great write up,

I was reading somewhere you could remove the stock mufflers w/o removing the rear cover. This will be a one man job unfortunately, I read you could use ramps on the rears and remove only the brace, possible?

Thanks

Installing AWE mufflers only no cats or headers. 2006 911s 6speed

Thanks

[Dave07997S]

Hi great write up,

I was reading somewhere you could remove the stock mufflers w/o removing the rear cover. This will be a one man job unfortunately, I read you could use ramps on the rears and remove only the brace, possible?

Thanks

Installing AWE mufflers only no cats or headers. 2006 911s 6speed

Thanks

You don't need to remove bumper cover to remove and install mufflers...just an FYI..

I installed my whole exhaust system (headers, mufflers and cats) in 3.5 hrs. with the car backed up on thick phone books. You don't need to remove the bumper cover nor the wheels.

Dave

Edited April 11, 2009 by Dave07997S

[anthonycocca]

Great write-up. I did it on a 996 w/out removing anything . . .

I do have a question, though. How about the PSE vaccum actuators? I have a 997 now and I'm wondering how they come into play w/the exhaust swap.....

Thx and again, nice job.

[anthonycocca]

Comes off from underneath by unbolting the 3 nuts from the triangle support and then the muffler clamp, no?