Thermal Reactor By-pass Headers - Installation Tips
 

Hi guys - just got a used set of headers for my '77 911s 2.7 and will finally be able to chuck the thermal reactors (!). I am wondering what the installation is going to be like - am I going to encounter broken studs, or break them? Should I soak them overnight with something like PB Blaster? Anyone who has done this job - your input is welcome.

TIA!

Do PB blaster for several days. Every 24 hours for 4-5 days before you start. Hit the studs w/ a small sledge each time (not too hard). The vibration helps.

chances are the reactors have been on since new ?

if so take the car in to a 911 shop or you'll be paying plenty to straighten up your mess.

the TR exhaust and heat exchangers constrict exhaust big time. Even with the mod headers to the heat exchangers they suck. Get a used set of SSI. Your muffler should be 2 in so you can still use that.

Forget about the PB blaster or other penetrating oils. These are the infamous "necked down studs" in these models. Heat the nuts cherry red with a torch and spin them off while they're hot - have the wrench/socket ready. Carefully chase the stud threads and use new nuts with thread anti-seize compound upon installation of the three- to-ones. Some go as far as heating the heads at the stud base and removing the necked down studs and replacing them with normal cross-section steel studs. Chances are you'll break a stud despite these measures but good luck!