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914World.com _ 914World Garage _ Heat Exchanger Removal

Posted by: solex Mar 18 2006, 03:16 PM

Hello,
I'm in the process of removing the entire exhaust system from my 75 with the intention of back-dating. I remove all of the exhaust stud nuts and the muffler. It looks like the exhaust tubes are pretty tight against the push-rod tubes.

In addition, the drivers side is not really moving around. Any tips on what I should remove to get the heat exchangers out?

Thanks,
Dan

Posted by: Mueller Mar 18 2006, 03:21 PM

and a piece of wood to use as a lever......

Posted by: joeav8tor Mar 18 2006, 07:14 PM

Dan,
I removed my exhaust system last year...remove the 8 nuts that hold the exhaust pipe/ heat exchanger from the engine...most of them will be easy to get to, remove those first then you can wiggle the heat exchanger a bit which will allow you to get to the hard to get nuts...try to use a thin walled socket (possibly 13mm) I ground down a socket to make it work...after the nuts are off the exhaust should come off of the studs...there is a spacer type washer (oval) between the engine and the heat exchanger...where are you located on Long Island?
Joe

Posted by: solex Mar 18 2006, 11:13 PM

Hey Guys,
Thanks for the tips. I got the passenger's side off with a piece of wood. The PO use a large diameter stud on the drivers side and am having difficulty getting the HE off. I had to heat/cut the nut but now the HE tab is binding on the larger stud. I will work on it tomorrow.

Joe, I'm in New Hyde Park. One of these days we have to meet up, I've got to see your 914.

Dan

Posted by: blitZ Mar 19 2006, 08:21 AM

QUOTE (solex @ Mar 18 2006, 09:13 PM)
Hey Guys,
Thanks for the tips. I got the passenger's side off with a piece of wood. The PO use a large diameter stud on the drivers side and am having difficulty getting the HE off. I had to heat/cut the nut but now the HE tab is binding on the larger stud. I will work on it tomorrow.

Joe, I'm in New Hyde Park. One of these days we have to meet up, I've got to see your 914.

Dan

I did the same thing a few months ago. Had to encourage the manifold off with a crowbar. Luckily, I had only one stubborn nut between the manifold and the HE, which I could reach with the Dremel. It's all worth it getting that wretched late model exhaust removed.

Posted by: rhodyguy Mar 19 2006, 08:36 AM

the worst design ever. too many connections and horribly rusted fasteners. ultimately i just cut it off in sections with a sawsall and angle grinder, leaving just the stub tubes. then it was pbblaster time. i would'nt worry about saving much of the late he'sstuff. very little of the ducting (if any) is going to apply when you install the earlier setup.

k

Posted by: solex Mar 19 2006, 01:20 PM

Finally got the entire system OFF

I needed a digging bar and had to cut a few more nuts, what a pain in the ass.

Any ideas on how to chase the outboard threads on the exhaust ports, looks a little too tight for my die???

Thanks for your suggestions.
Dan

Posted by: rhodyguy Mar 19 2006, 01:31 PM

double nut the old studs and carefully remove them. get new ones. a thin wall (1/4" drive) socket works much better torqueing the new setup on. look for the nuts that are the 12mm flavor, not the 13s.

k

Posted by: solex Mar 21 2006, 10:43 AM

Hello all I got the offending stud out. I measured it as 10 x 1.5. Also I measured the "stock" studs and they appear to be 9 x 1.25?

3 questions:

(1) Is the stock stud 8 x 1.25 or 9 x 1.25?
(2) Where can I get a step stud for this application?
(3) Do I use loctite on the studs?

Thanks,
Dan

Posted by: TROJANMAN Mar 21 2006, 10:47 AM

you're a week ahead of me..........

my stuff is coming off next weekend.