What should I do or not do about this exhaust issue??

[hwgunner]

OK, I have a 77 2.7 motor that I am going to stick in my 73 911. The motor came to me as a good running motor from a local Independent shop that took it out of a customers car for a 3.2 swap. As usual I got it home and couldn't leave well enough alone. I completely removed the induction system and am knee deep in that but also wanted to remove the heat ex-changers to to get a good look at the oil return tubes. Well here is what I found under the passenger side. The ex-changers are Dansk thin flange and were held on by a reamed out nut, 2 washers and 12mm split nut. They were very difficult to get to but none of them were that tight. You can see in the first picture that the exhaust was leaking, hence the black soot all over the mating surface. In the second picture there is a bunch of red RTV/Silicon and in the third picture you can see one of the studs is bent. It was this way when the exhaust was installed as evidenced by the 4th picture and the notching of the gasket. This was the only gasket that was notched.

So I am trying to do this my self and need to know what to do now. Fix it or button it up and forget about it. I plan on running a header and M&K Exhaust. If the answer is fix it then what is the fix?? Can I do it myself. As for my ability I typically tell people I couldn't put it back together for the last jelly donut on earth but truth is I like to wrench a little and can follow instruction pretty well.

Thanks in advance for the help.

jonathan
hwgunner

[Ronnie's.930]

If the studs are intact and useable, then I would suggest that you leave them alone and see how they line-up and fasten-down with your new headers . . . replacing exhaust studs is not something for a novice mechanic to undertake . . .