Porsche 987 Boxster Exhaust Install

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Written By: DriveDIY (and one other contributor)
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Difficulty

Moderate

Steps

16

Time Required

03:00:00 - 05:00:00

Sections

2

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Introduction

This guides shows a detailed installation of a Fabspeed 987.1 Maxflow Exhaust System

  1. Using one of the REAR factory jack points. Jack up vehicle and place a jack stand under the front jack points. Carefully position the jack stand to correctly contact that jack point of the vehicle

    • Using one of the REAR factory jack points. Jack up vehicle and place a jack stand under the front jack points.

    • Carefully position the jack stand to correctly contact that jack point of the vehicle

    • Repeat this procedure on opposite side of vehicle.

    • The Porsche Factory jack points are designed for pin top style jack pads. While a normal jack will work, the pin top ones are the safest to use and safest for the vehicle.

    Edit

  2. Using a low profile jack, center the jack directly in front of the engine and using chassis cross member, lift vehicle and place jack stands on rear jack points. Photo #1 is 991 Cross Member Photo #2 is 997.2 Cross Member

    • Using a low profile jack, center the jack directly in front of the engine and using chassis cross member, lift vehicle and place jack stands on rear jack points.

    • Photo #1 is 991 Cross Member

    • Photo #2 is 997.2 Cross Member

    • Photo 3 Shows a Cayman/Boxster rear jack point with optional jacking block.

    Edit

  3. Place a solid jack stand under the 4 jack points located near each respective wheel.

    • Place a solid jack stand under the 4 jack points located near each respective wheel.

    Edit

  4. Insert wisdom here. Insert wisdom here.

    • Insert wisdom here.

    Edit

  5. Remove the Driver and Pass side plastic shields to gain access to the exhaust flange bolts

    • Remove the Driver and Pass side plastic shields to gain access to the exhaust flange bolts

    • 10MM Plastic Nuts

    • T-25 Torx Screw

    Edit

  6. Expect Extensive Corrosion! Soak everything in a penetrating oil like PB Blaster for atleast 15-30 min ... We will address at a later step how to remove any broken studs.

    • Expect Extensive Corrosion! Soak everything in a penetrating oil like PB Blaster for atleast 15-30 min ... We will address at a later step how to remove any broken studs.

    • The Drive side offers easier access to the flange nuts

    • 13mm Nut

    • Using a combination of universal joint sockets and open ended 13mm wrenches... when loosening the nuts, take extreme care to not snap the studs off. Avoid putting a side load on the bolts.

    Edit
  7. Edit

    • Loosen 16mm Clamp

    • Wiggle Exhaust Tip Loose

    Edit
  9. Edit

  10. Carefully lift exhaust off exhaust studs and suspension

    • Carefully lift exhaust off exhaust studs and suspension

    Edit

  11. Ensure exhaust gasket is still attached to flange. Broken Stud (before removal)

    • Ensure exhaust gasket is still attached to flange.

    • Broken Stud (before removal)

    Edit

    • Apply heat using a MAPP Torch to the flange

    • Try and concentrate the heat on the flange to help it expand.

    • After around 30 seconds of heat, use a punch and hammer to knock broken stud out

    • Remove Gasket Before starting this

    Edit

  13. Use new 13mm nuts when mounting the exhaust pipes to flange

    • Use new 13mm nuts when mounting the exhaust pipes to flange

    • Fabspeed Supplied replacement nuts for this application

    • Tighten to 17ft/lb

    Edit

  14. Photo shows Fabspeed supplied rubber gasket

    • Photo shows Fabspeed supplied rubber gasket

    Edit
  15. Edit
  16. Edit
Finish Line

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DriveDIY

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