Pelican Technical Article: Muffler Replacement Wayne R. Dempsey
Time: 2 hr
Tab: $500-$1000
Talent:
Tools:
-
Applicable Models:
986 Boxster (1997-04) 987 Boxster (2005-08)
Parts Required:
New muffler
Hot Tip:
Have a friend help you lower the muffler, as you don't really want it to fall on your face
Performance Gain:
Sportier sound
Complementary Modification:
Replace catalytic converters
This article is one in a series that have been released in conjunction with Wayne's new book, 101 Performance Projects for Your Porsche Boxster. The book contains 312 pages of full color projects detailing everything from performance mods to changing your brake pads. With more than 950+ full-color glossy photos accompanying extensive step-by-step procedures, this book is required reading in any Boxster owner's collection. The book is currently available and in stock now. See The Official Book Website for more details.
Check out some other sample projects from the book:
One of the easiest and easily rewarding upgrades you can perform on your Boxster is to upgrade your muffler. Today's modern sports cars have exhaust systems that don't wear out as much as in the past, but there's still a definite need to upgrade to that sporty sound. Luckily, on the 1997-04, you can upgrade to a sport muffler pretty easily.
The process is quite simple: jack up the car, undo the brackets and pipes and then drop down the muffler. I would definitely recommend having a buddy help you with the process: these mufflers are heavy and can be unwieldy, particularly underneath the car. Have a friend hold the muffler up into the car when you disconnect the brackets. Also, the removal of the muffler is made easier if you remove the rear bumper first, as you will have easier access to all of the mounting brackets.
The Dansk stainless steel sport muffler shown here is a great addition to your Boxster. Similar, if not identical to the sport muffler option provided on the Boxster S, the Dansk system is designed to give a sportier exhaust sound, all the while reducing backpressure and increasing horsepower. I have not personally tested its performance on the dyno (Pelican Technical Article: Dyno Testing), but it certainly sounds great, and is pretty easy to install. For a higher performance system that includes high-flow catalytic converters, see Pelican Technical Article: Installing a Performance Exhaust System.
Figure 1
Shown here is the very cool-looking underside of the Boxster (1997-04). There are a few pipes and brackets that need to be disconnected in order to remove the muffler. Items A/B/C/D correspond to the close-up shots in Figure 2.
A- This is the catalytic converter side of the u-shaped pipe. Two clamps hold this connection together. B- The other side of the u-shaped pipe is clamped to the muffler. C- The topside of the muffler is bolted to the bracket on the back of the transmission. See the blue arrows in Photo 3 for details on the studs that connect to this bracket. D- The rear catalytic converters are supported by a small bracket shown here which is attached to the muffler.
Here's a shot of the top of a Dansk sport muffler. The top muffler bracket that spans the length of the muffler is attached to studs welded onto the muffler (orange arrow). The bracket has studs that then mate with the bracket that is affixed to the transmission. The whole goofy setup seems way too complicated to me, but it appears to work fine.
In 2005, Porsche redesigned the whole exhaust system and made it a lot simpler. The muffler now has a built-in catalytic converter. It's attached at the rear of the car (yellow arrows), and also supported by clamps in the middle (red arrow). An additional bracket in the center provides additional support (green arrow). The mufflers are attached to the exhaust manifolds all the way on the other side of the axles (orange arrows).
Comments: Are there any articles or photos that have a descriptive explanation for removing the rear bumper?
October 2, 2011
Followup from the Pelican Staff: Sorry, I do not have anything explicit. It's similar to the front bumper, which we have an article on though. I'll copy this to the forums, perhaps someone there has some photos or tips... - Wayne at Pelican Parts
Tony
Comments: Hi. I recently replaced the passenger side catalytic converter and O2 sensors on a 1999 Boxster. Now, the car rhythmically idles at 1500-2000 rpms. It does this when the engine is cold and when at driving temperature. Does this sound familiar? I would appreciate any advice you might share.
Thanks.
May 2, 2011
Followup from the Pelican Staff: "rhythmically idles" - is that like a "hunting idle"? Those are almost always caused by mixture problems, which the O2 sensor is supposed to regulate. I would check the trouble codes to see if the car is telling you what is wrong with it. See my procedure here: http://www.pelicanparts.com/techarticles/Boxster_Tech/20-FUEL-Code_Reading/20-FUEL-Code_Reading.htm - Wayne at Pelican Parts
Check out some other sample projects from the book:
