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Pelican Technical Article:

Muffler Replacement

Steve Vernon

Time:

1hours

Tab:

$360

Talent:

**

Tools:

14mm (2), 13mm socket, extensions, floor jack, jack stands, wheel chocks, safety glasses, torque wrench, penetrating oil

Applicable Models:

Porsche 944 (1983-89)
Porsche 944 S2 (1989-91)
Porsche 944 Turbo (1986-89)
Porsche 944S (1987-88)

Parts Required:

Muffler

Hot Tip:

Get a friend to help

Performance Gain:

Better sounds

Changing out the stock muffler on a car is one of the most popular modifications people do to their vehicles. Replacing the muffler on the Porsche 944 and 951 is simple and easy. The only issue is it is a little awkward. If you have any doubts about whether you can lift or handle it get a friend to help. It is a good idea to spray the hardware with penetrating oil for a week or so before you plan on removing it and let it heat cycle a few times. Even doing this you should be prepared for some of the studs to break. Make sure you are working on a cold exhaust system.

To remove the muffler you will need to safely raise and support the vehicle. Please see our article on safely raising and supporting your Porsche 944 or 951.

To remove the muffler you will need to work on three areas: the rear hangers (red arrows), the catalytic convertor flange (yellow arrow) and the middle hanger (green arrow).
Figure 1

To remove the muffler you will need to work on three areas: the rear hangers (red arrows), the catalytic convertor flange (yellow arrow) and the middle hanger (green arrow).

The rear of the muffler hangs from two rubber isolators (red arrow, one shown).
Figure 2

The rear of the muffler hangs from two rubber isolators (red arrow, one shown).

Make sure to spray the hardware with some good penetrating oil and try and do it several times over the course of a week or so, so it can get some heat cycles.
Figure 3

Make sure to spray the hardware with some good penetrating oil and try and do it several times over the course of a week or so, so it can get some heat cycles.

There is a hanger just in front of the flange (yellow arrow).
Figure 4

There is a hanger just in front of the flange (yellow arrow). Make sure you inspect the condition of the rubber hanger (red arrow) before removing the flange bolts. If the rubber hanger is broken, the exhaust will drop on your head when you remove the hardware.

Inspect the condition of the hangers for the catalytic pipe as well before you remove the flange hardware.
Figure 5

Inspect the condition of the hangers for the catalytic pipe as well before you remove the flange hardware. The hangers on our cat pipe were missing so we supported it first (red arrow) and then removed the hardware. Separate the pipes and let the pipe hang on its hanger (yellow arrow).

Use a 13mm socket and extension and remove the two rear hangers from the chassis (red arrows).
Figure 6

Use a 13mm socket and extension and remove the two rear hangers from the chassis (red arrows). Have a friend hold the muffler or keep a hand on it. Once you remove the hangers the muffler is free to fall. Remove the muffler and angle it of the hanger by the catalytic converter.

If you are replacing the muffler this is also a good time to check the condition of the rubber hangers/isolators (red arrows) and replace as needed.
Figure 7

If you are replacing the muffler this is also a good time to check the condition of the rubber hangers/isolators (red arrows) and replace as needed.

Now a good time to also check the condition of the rubber hanger/isolator (red arrow) on the flange and replace as needed.
Figure 8

Now a good time to also check the condition of the rubber hanger/isolator (red arrow) on the flange and replace as needed. Installation is the reverse of removal.



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