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Pelican Technical Article:

Muffler Replacement

Time:

2 hr

Tab:

$500 to $1,000

Talent:

**

Applicable Models:

Porsche 986 Boxster (1997-04)
Porsche 986 Boxster S (2000-04)
Porsche 987 Boxster (2005-12)
Porsche 987 Boxster S (2005-12)

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
101 Performance Projects for Your Porsche Boxster

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.

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.

Shown here is the very cool-looking underside of the Boxster (1997-04).
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.
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.
Figure 3

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.
Figure 4

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).

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Comments and Suggestions:
ncfonz Comments: The later 04 muffler on a Boxster has a flat bar mount going across the top of the muffler, looks a lot stronger ! Will this complete muffler Assy fit a 97 Boxster ?
May 15, 2016
  Followup from the Pelican Staff: I don't believe so. If possible, you may be able to swap the mount.

Give The Pelican Parts parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.

- Nick at Pelican Parts
 
Robert Comments: Does the bumper need to come off for a 1998 boxster base Tiptronic?
February 4, 2016
  Followup from the Pelican Staff: Yes. - Nick at Pelican Parts  
Bonesy Comments: Hi can you tell me if the cats on the 96.20 systems & the 96.21/22/23/24 systems are interchangeable? Looking at items 13 & 14 on this diagram.
Thanks Mark
http://www.scuderiacarparts.com/diagram/porsche/boxster-1997/fuel-and-exhaust/exhaust-system-m-9620/138-547-21463.html
Ps its a Uk spec car 2004 2.7s manual
November 2, 2015
  Followup from the Pelican Staff: Only if the part numbers match. Give our parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
Yaridaboss Comments: What is the inside and outside diameter of the u pipe? figure b
-01 986 2.7
October 21, 2015
  Followup from the Pelican Staff: I don't have that info. Give our parts specialists a call at 1-888-280-7799. They can figure it out.
- Nick at Pelican Parts
 
offpistesau Comments: hello there, how is the long bracket in fig 3 orange arrows fixed to the muffler? i have bought a used muffler w/o this bracket. thanks a lot.
June 1, 2015
  Followup from the Pelican Staff: I am not sure of the length. You could measure the mounting points on the new muffler.

I opened a post in our forums. A Pelican community member may be able to answer your question.
- Nick at Pelican Parts
 
robert Comments: I have 99.. I bought a later model dual exhaust and I have pieced together the brackets to mount it. Since I didn't buy the complete sport exhaust mounting kit, I don't have the bolts to bolt the cast bracket onto the trans. Do you know what sizes these are so that I can order them and then do this in one fell swoop. I have a friend with a shop and lift, but I can't leave the car there while I order the correct bolts. thanks, robert

Yeah I know it is just cosmetic, but I got a good deal on the muffler and the brackets.
March 24, 2015
  Followup from the Pelican Staff: I don't know the botl sizes.

Give our parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
Andy Comments: Nick,

I called customer service, but they don't know what repair manual you are referring too. I already purchased the 101 Boxster projects but need a totally comprehensive service manual... many thanks
February 9, 2015
  Followup from the Pelican Staff: Bentley makes a nice manual:

http://www.pelicanparts.com/cgi-bin/ksearch/pel_search_2014.cgi?SUPERCAT_FLAG=Y&make=POR&Context_make=POR&please_wait=N&LastVisited_input=&Previous_Section=&forumid=&threadid=&command=DWsearch&description=bentley&I1.x=0&I1.y =0 - Nick at Pelican Parts
 
Andy Comments: I am about to replace the exhaust to cat gasket along with the corroded nuts and bolts. Is there any special procedure for this other than switching the new parts in? Should I be using some kind of compound in the joint or on the nuts etc and do you know the torque spec for the three nuts?
February 6, 2015
  Followup from the Pelican Staff: No coatings or special procedure, other than the tightening sequence and torque. I would grab a repair manual. It will have the procedure, special tools and torque specs.

Give our parts specialists a call at 1-888-280-7799. - Nick at Pelican Parts
 
OttawaMan Comments: I'm in need to replace the two clamps on either side of the central tail exhaust on my 2006 Cayman S but all I can find is a part for a 986. Are the pipe diameters the same so that I can use the 986 part or is there a part I can order for my 987?
May 23, 2014
  Followup from the Pelican Staff: I am not 100% sure. Give our parts specialists a call at 1-888-280-7799 and they can help figure out which part or repair kit you need.
- Nick at Pelican Parts
 
Rich Jones Comments: Found my problem, its common, 3 bolts holding 2 flanges together downwind of 1st cat have given up. No sign of any nuts, just the remnant spikes and 2 inner-most wont budge, were these really a bolts?
Drivers side looks the same but they're still holding, again no nuts in sight.
I've improvised clamps from bent washers and M6 nuts/bolts to hold flanges together for now and applied "home brew" atf+acetone each day, will try to remove all of them at wkend.

Are better bolts available? The one I removed has external splines from thread up to the head.
May 20, 2014
  Followup from the Pelican Staff: Thanks for the follow up. We appreciate it.
- Nick at Pelican Parts
 
Rich Jones Comments: 987 exhaust blowing after driving through puddle: jacked up and found the 3 bolts at the flange above axle have failed
May 13, 2014
  Followup from the Pelican Staff: At the exhaust manifold? You will have to remove the exhaust and replace the studs. - Nick at Pelican Parts  
Rich_Jones Comments: Are the bolts with red arrows in the 2005 photo http://www.pelicanparts.com/techarticles/Boxster_Tech/46-EXHAUST-Muffler/images_med/Pic4.jpg a kind of clamp holding the back box on to the over-wheel "down pipes"?

I just drove through a deep puddle 7-8", theres now a loud blowing noise so I hope it's just a clamp that's shock-cooled and given way.
May 13, 2014
  Followup from the Pelican Staff: The red arrows point to mounting straps. - Nick at Pelican Parts  
Chris Comments: Hi Nick

I have a 2003 facelift 3.2S tiptronic. Can I replace the muffler without taking off the back bumper?

Regards
Chris
April 22, 2014
  Followup from the Pelican Staff: If I remember correctly, the rear bumper has to come off. - Nick at Pelican Parts  
aqmobile Comments: A friend of mine gave me a Borla exhaust from his 2006 Cayman S. Will it fit my 2002 Boxster S? Thanks!
April 21, 2014
  Followup from the Pelican Staff: I don't think so. You can call Borla and check the part numbers. - Nick at Pelican Parts  
Derrick Comments: Actually, I meant the bolts that were pointed to in a teal like color in figure 3, I am having a very hard time getting those off as the heads are very thin.
April 7, 2014
  Followup from the Pelican Staff: got it, thanks. - Nick at Pelican Parts  
Derrick Comments: Hello, I need a little bit of help with some horribly rusted bolts....how would you recommend going about removing them? I have tried lubricant and wound up just breaking a bolt. Im letting the rest soak overnight in hopes that they come a little bit more loose.
Also in Figure 1 and 2, the C bolts. They have very very thin heads, and my sockets keep slipping off them. How else would I go about removing them, any tools I should consider buying/using? Im afraid to strip them.

I have a 2001 Boxster which has apparently seen its fair share of Maryland winters.
April 7, 2014
  Followup from the Pelican Staff: Once soaked, you can try to loosen them If they do not loosen, you may need to apply heat to the nut. Once you heat them they should come off. If the nut strips, try hammering a smaller size 12 point socket over it. - Nick at Pelican Parts  
noirpanther Comments: I have a 1997 Boxster 2.5L, 135,000 km. It was slightly hilly front when I bought it. I repaired it and it runs great for 5 years. For some time it has an unusual sound that seems to come from the muffler or transmission when I quickly rolled the first 30 feet and only in first gear. It looks suspiciously like a vibration plate. I did make an inspection to the garage and they are not if the noise comes from the muffler or transmission. Do you have any idea what could cause this strange noise?
February 13, 2014
  Followup from the Pelican Staff: I would inspect the heat shields. One could be loose and causing this noise. - Nick at Pelican Parts  
robin Comments: I read somewhere that I need to remove the rear bumper to get access to the nuts holding the muffler in place. Can I really take the muffler off without removing the bumper ?
November 29, 2013
  Followup from the Pelican Staff: What is the year and model of the vehicle? - Nick at Pelican Parts  
clueless Comments: Wayne,
How many catalytic converters are there on a 1999 Boxster 2.5L?
May 3, 2013
  Followup from the Pelican Staff: Two, one for each side of the engine. - Nick at Pelican Parts  
B52EWO Comments: I was wrong about there being no catalytic converter in the muffler or silencer as Porsche calls it. The documentation I have indicates the exhaust manifold contains the PRIMARY catalytic converter which they are replacing on my Boxster S and the muffler contains an integrated catalytic converter. Thank you very much for clearing that up and for offering these technical articles for us do-it-yourselfers. Because of this resource, I will be using your company for any parts needs I may have in the future.
April 10, 2013
  Followup from the Pelican Staff: No sweat, that's what we're here for! - Wayne at Pelican Parts  
B52EWO Comments: I don't believe you are correct about the catalytic converters on the 05 Boxster. They are part of the exhaust manifolds and are not part of the mufflers. I'm in the middle of an effort to have them replaced under the 8 year/80,000 mile warranty required by the EPA for all autos built after 1995. For your readers: If the "Placed in Service" date is not over 8 years ago and you have less than 80,000 miles on the car, they are covered. I didn't know about this until I called the local Meineke shop to inquire about an after market converter and he told me about it.
April 9, 2013
  Followup from the Pelican Staff: Just to make sure I wasn't going crazy, I checked the Porsche factory parts diagrams. They list PN 987-113-111-04 for 2005 as "muffler with Main Catalytic converter" for cylinders 1-3. What you're thinking of are the exhaust manifolds with the pre-catalytic converters built in (the car has a total of four converters).

Thanks for the tip about the EPA equipment - most people don't know that there is an eight-year warranty on these. It is important to note, however, that if the car has been running rich, then it can damage the converters, and they might not be covered under the warranty. - Wayne at Pelican Parts
 
Garrytw 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  

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