Exhaust bracket stud broken - to worry?

[jchapura]

I swapped out my 997 C2S mufflers for Gundo-hacked mufflers but in doing so I broke off one stud of three that's on the exhaust bracket (just too corroded I guess).

 

I buttoned everything back up because I didn't have another bracket but was wondering if I should preemptively order a new bracket before something worse happens. The bracket part number is 996.111.238.03.

 

I'll certainly listen for squeaks and vibrations...

[Hilux2400]

This happened to me on my 996.  I drilled out the sheared studs and replaced them with a short stainless steel bolts, washers and Aerotight stainless steel lock nuts. There just enough room to get a spanner in to tigthten them up.

 

I don't think I would want to run with just two bolts for too long.  The exhaust box is heavy and it will vibrate as it is subject to opposing movement (up and down) as the engine rocks on its mountings. This will also place stress on the joint between the cat and the box and header pipe and the box.  Watch out from the rear to make sure your tail pipe end is not drooping as this could be an early sign that you need that extra bolt.

 

The other thing I did was to insert the long mounting bolts from the bottom and not the top, once again locked with Aerotight nuts.  This means that the next time I need to take off the box I will only need to drop out the long bolts and leave the mounting in place. 

[jchapura]

Thanks Hilux2400.

 

I did swap ends on the long mounting bolts you described.

 

Did you make a spanner wrench for that (I think) 13 mm bolt? If I remember right it was very tight on the backside of that bracket. But maybe I have a cheapie spanner wrench from my bicycle maintenance (cone nuts and locking nuts).

[Hilux2400]

You're right it is a13mm spanner, but when I put the mounting plate on the box was not in place so I had quite a bit of room.

 

When I took it apart I had to do it with the box in place, which was pretty tight. I think I used a socket wrench to get the nuts off that's how I was able to shear off the very rusty ones. 

 

As you have now put it all back together you will not be able to insert a bolt as the flat head of the old bolt will still be in place. You might have to take the box off again to get it right. But it should be easy the second time.