Re: Exhaust Downpipe replacement tips? - Saab 900 Bulletin Board - Saabnet.com
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Re: Exhaust Downpipe replacement tips?
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Posted by pursang (more from pursang) on Fri, 20 Jun 2003 09:00:19 Share Post by Email
In Reply to: Exhaust Downpipe replacement tips?, Paul [Profile/Gallery] , Fri, 20 Jun 2003 08:43:29
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When I did mine, I used a Dremel cutting disc mounted on their flexible drive extension to saw through the 4 nuts holding on the lower pipe. (Mine had cracked at the weld and needed replacement). I figured that the age and heat factors would result in a busted stud and would require replacing the exhaust manifold which just presents more of the same breaking stud issues. ( I assume my 92 900 n/a setup is similar to your year).

Try to cut down the side of the nut without cutting into the threads on the stud. Once you are about 3/4th the way through, you can stick a big flatblade screwdriver in the slot you cut and twist the nut apart, like a nut breaker, (which can't get into that close space) sparing stress on the stud. I had problems getting the new nuts to stay on tight, someone recommended special "crushed" nuts, or slightly ovoid nuts to stay on without loosening. Check with the dealer on those before the day is out, or do it later if you have the same problems I had. Also use new gaskets.

Buy the larger Dremel fiberglass reinforced discs at Home Depot and buy a lot of them; 12 or so. you tend to break them until you get the feel for them, use high speed, steady hand and light pressure, let the cutting edge do the work.

And wear eye protection, seriously. Good luck, let us know how you make out.

92 900S 5 speed n/a 193,500 miles

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