kjopen

Here's an update for anyone planning on tackling this job:

There was no way on earth I could get the new cat/pipe in place with just the front of the car jacked up as shown in 'LR Audi's photos - and I tried for hours and had the car very high on my 6 Ton axle stands. So, I decided to raise the car by its side with the 6 Ton axle stands supporting front and back and with ramps and wood under each wheel for safety. It was quite a struggle even then to get the cat/pipe in place. When I tackle the drivers side cat/pipe I may see if I can borrow a lift or maybe even take the car to an exhaust fitter and let them do it.

Another note: I ordered both cats/pipe from a major exhaust seller on ebay, although the parts looked similar on their photo's they were slightly different, the welded on 'hanging brackets' were not present, I only noticed this when I finally opened the package which was then passed the 30 day return period (I had to travel away unexpectedly). Finally on fitting, the overall length of the cat/pipe is 1 & 1/2 inches too small! So I'm looking for options as the exhaust is blowing around the sleeve fixing in the middle of the car. I don't have welding gear.... so I'm thinking of cutting a 1 & 1/2 piece of pipe from the old pipe and fitting it in the slot then buying and fitting a new sleeve in the hope the damn thing seals. I don't think it will and I may end up having to get a piece welded in.

LR Audi

Even though it has been a long time, I remember the biggest difficulty I had was reaching the bolt that attach the cats to the exhaust manifolds. I have 4 ton axle stands, which to this day I still use. I used them not too long ago on my S8 V10. I'm surprised you didn't get enough clearance, 6 ton axle stands should be much higher than mine. I can't comment too much on the exhaust manufacturer, but I do remember the dealership wanting an absurd amount of money for an OEM part.

I hope things work out for you!

kjopen

You're right about the dealership price - scary. I too struggled with that top nut on the manifold but a 13mm stubby saved me (but not my knuckles!). The reason I struggled with the cat/pipe is because mine has a pre-cat at the top - your was a straight pipe, I guess although they are both C5's mine is a 2001 I'm guessing yours was maybe a 1999 perhaps.

I'll be making the cut-out pipe for mine today and trying the finish the one side.

If anyone is interested, I will post photo's and report status - but I'm guessing not many people have these old cars now...