1. Lubricate all the bolts with a penetrating oil\ 13mm
2. Loosen the 4 nuts that hold on the 4” factory clamp
3. Then slide the clamp over towards the cat
4. Loosen the 2 nuts that hold the cats to the mufflers
5. Remove nuts on the bottom brackets that hold the muffler
6. Remove bolts on the 3 bolt flange where the headers meet the mid pipe
7. Remove the top mounts by taking off the 2 13 mm bolts and nuts that hold the top mount
8. Then carefully rotate the muffler facing the tip towards the floor the muffler will slide down and out the bottom
Here is a follow up detailing the installation of the Fabspeed Maxflo mufflers with secondary catalytic converter bypass pipes and polished tips.
1. INVENTORY OF PARTS
2. INSTALL THE FABSPEED BOX MOUNT TO THE TOP MOUNTING BRACKET
3. PUT THE 2.25" CLAMP ON THE PIPE THAT JOINS THE MUFFLERS TOGETHER; SLIDE THE MUFFLERS TOGETHER
4. LIFT THE MUFFLERS UP IN PLACE; this will take two people as one person holds the mufflers up against the top bracket and the other person puts the large band strap around the muffler through the box style hanger-->start the nut but do not tighten
5. INSTALL THE FABSPEED BOTTOM BRACKET TO THE MOUNT AND PLACE MUFFLER BAND STRAP THROUGH BRACKET--> do not tighten
6. PLACE THE 2.25" CLAMP AROUND THE MID-PIPE THEN INSTALL The 3 BOLT FLANGE SECTION ONTO THE PIPE
7. SLIDE THE MID-PIPE THROUGH THE CAR AND ATTACH THE 3 BOLT FLANGE TO THE HEADERS USING THE COPPER GASKET--> BOLT TOGETHER BUT DO NOT TIGHTEN. PLACE THE BACK OF THE PIPE INTO THE MUFFLER USING THE V-BAND CLAMP-->DO NOT TIGHTEN
8. TIGHTEN THE 3 BOLT FLANGE TO SEAL WHERE THE INLET PIPES MEET THE HEADERS, TIGHTEN THE CLAMP THATS JOINGS THE FLANGE TO THE AXLE PIPE
9. TIGHTEN ALL BOLTS STARTING AT THE BACK OF THE SYSTEM. THERE ARE TWO CLAMPS AROUND THE AXLE PIPES (Tighten all bolts starting at the back of the system clamps around the muffler all brackets working your way from back to front while adjusting everything to align the tips)
10. Last fine tune the tips by tightening them last making the appearance perfect.
I like the bellows in the connector pipe from the headers to the mufflers. All systems should have that, if for no other reason than to allow for differential thermal expansion. Nice...
The bellows on the axle pipes also provide more adjustability when installing our Maxflo mufflers to ensure a proper fit and cut down on install time.
I'm guessing that's a 986. Correct?
Having done a couple of 987 exhaust installs, that looks just a little different....
Yes this exhaust setup is for the 986 Boxster/S 2000-2004 only. We redesigned the muffler brackets to reduce the resonance/drone by utilizing the stock mounts instead of the supplied brace on our previous system. The stock muffler mounts are designed to absorb vibration and decrease the resonance of the exhaust. The 987 Boxster/Cayman still uses the supplied brace and "A & B" mounting brackets.
