So, I was removing my center muffler today, and accidentally snapped one of the three bolts (the outermost one) that attaches the center muffler to the catalytic converter. It was rather rusty, and I should have let the WD-40 soak in a bit more before attempting to wrench on it.

I looked at on the cat side, and it appears to be a rounded head. Can the bolt easily be replaced? Not sure how to proceed on it.

Darn new england weather and all the salt on the road...really corroded those nuts and bolts after two full winters...

 

Those are a press fit into the flange, you're not going to get it to back out. What you will have to do is cut the remaining stud flush to the flange (Thank doG that is easy to get to on the outside one), and then drill out the bolt, starting with a small bit and working it up in size. An pneumatic cut-off wheel will trim that stud in about 10 seconds, but if you don't have one of those a hacksaw will work.

Once you get it fully drilled out it may pop out with a hit from the hammer using a punch, but if not just replace it with a nut and bolt. Use Copper Anti-Seize paste on re-assembly to prevent that in the future.

WD40 doesn't do a very good job loosening that kind of fastener, its more a lubricant than a rust-breaker. I use one of these products, with the LOCTITE FREEZE one my favorite, so far its never failed me - its an incredible product and I use it all the time:



Or this and let it soak for a few hours - what I used to use before discovering the FREEZE product:

 

I would just hit up your SA at the dealer -- might even find you one around their shop. Porsche is great at re-using parts across applications in the same car, so maybe that bolt is common.

 

Sam thing happenned to me. No biggie. Just drill out the busted bolt and replace with a through bolt with washers and nut. You will be fine.

 

Thanks. I'll cut off the remaining piece, and try to drill it out / tap it out with a punch. Thankfully it was just one.

I am definitely getting some better penetrating spray, and some anti-seize.

 

Instead of drilling it all the way, first try drilling it, just enough, to get an "easy out" into the bolt. After hitting it with Locktite Freze you might be able to get it out.

 

Since it is pressed in, I am going to start with a clamp and see if I can press it back out the other end.

I figure that is easiest before taking it off to drill it out.

And I realized I definitely don't want to hammer on the cat.