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Porsche 997 Gen 1 Exhaust Manifold to Catalytic Converter Loose

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Good Day To All


Noticed increase nosie on Engine Start. Sounded like busted exhaust.


on investigation found blowing between Exhaust Manifold LHS and Catalytic converter. The nuts on all 3 screws are completely rusted and after cooling down the 2 parts can be separated slightly.


The 3 screws and locking nuts are shown on the parts diagram as not connected to the Cat.


My problem is that i can get the screws out to replace them with the exhaust still on the car.


Any advise 



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Hi, I did this about 2 years ago.  Just get a high speed 1/4" diameter x 20k rpm electric or pneumatic grinding tool and a bit with a fine pattern for carbon steel removal.  The tool I used is cylindrical with a spherical top.  Use eye protection (glasses + a face shield).  I removed the rear fascia and the heat insulation piece and you should have adequate space to grind the fasteners.

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