Porsche 997 Gen 1 Exhaust Manifold to Catalytic Converter Loose

[pmfakelly]

Good Day To All

 

Noticed increase nosie on Engine Start. Sounded like busted exhaust.

 

on investigation found blowing between Exhaust Manifold LHS and Catalytic converter. The nuts on all 3 screws are completely rusted and after cooling down the 2 parts can be separated slightly.

 

The 3 screws and locking nuts are shown on the parts diagram as not connected to the Cat.

 

My problem is that i can get the screws out to replace them with the exhaust still on the car.

 

Any advise 

 

thanks 

[racerken]

Hi, I did this about 2 years ago.  Just get a high speed 1/4" diameter x 20k rpm electric or pneumatic grinding tool and a bit with a fine pattern for carbon steel removal.  The tool I used is cylindrical with a spherical top.  Use eye protection (glasses + a face shield).  I removed the rear fascia and the heat insulation piece and you should have adequate space to grind the fasteners.