Hi all
Chris from the UK
2004 Dark Metallic Grey convertible...65000...6 Speed Manual

Developed a rattle when car hotmand have traced it to the passenger rear cat
Has anyone here replaced an exhaust system as it has become apparent that
one side unbollts at the cat but the other side is welded to the cat meaning
I guess that I have to disconnect from ths exhaust manifold flange and that looks
to be very tight and inaccessible up there
Any help pics guidance etc greatly appreciated
I am starting Kroil penetration soaking tomorrow and the new
exhaust arrived when i was half way through writing this
I absolutely love car....gearbox can be a bit notchy when cold and have
just replaced the steering box linkage bar
Just back with a fresh MOT...no advisories and not a hint of rust anywhere
Thanking you in advance
Chris
Lowestoft in Suffolk

 

Yes, you are correct about the left side cat (from the driver's point of view), it is welded in place. The exhaust system must be replaced, unless it's possible to cut out the old cats, and weld new ones in.
I haven't done mine yet. Here's a pic I found of the exhaust system for reference.

 

Thanks for pic
it's good to know how it sits off the car
Have discussed cutting the old cat out and welding a new one in its place
from an MOT point of view and possibly a rear cat delete and my local
MOT station tell me both actions COULD result in MOT failure
The guidelines are somewhat shady but state any obvious non factory
or removal of any necessary part of an exhaust system can result in a fail
chris

 

Our laws in the states are not as strict as yours, so we could most likely get away with cutting out and replacing. In your situation, your original plan of action would be the best choice.
Personally, on my car when the time comes, I will do the entire exhaust as well. I think letting the penetration oil do it's job overnight will be very helpful.
Perhaps removing the heat shields in the engine bay will provide better access to the manifold bolts.
Keep us advised of your progress. Best of luck to you!

 

I've developed the exact same problem. Thought about gutting the rear cats but don't know how that would effect the sound.