Removing Rear End

Information 

Only make cuts in the top plate. Make sure not to damage the plate underneath when doing this.

Fig 1: Rear End Component Location (Except Boxster, Boxster S, Boxster GTS)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Unscrew and remove flow drill screws -1-  .
   1. 1.1. Grind off welded seams -2-  .
   2. 1.2. Drill through punch rivets -3-  using a → Diameter: 6.6 mm  .
      Fig 2: Removing Rear End In Passenger Compartment Area (Except Boxster, Boxster S, Boxster GTS)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Remove filler plates at the left and right.

   Information 

   Drill out the connection point on one side only. Do not damage the plate underneath.

   1. 2.1. Drill out spotwelds -1;2-  .
   2. 2.2. Drill through punch rivets -3-  using a → Diameter: 6.6 mm  .
   3. 2.3. Unscrew and remove flow drill screws -4-  .
   4. 2.4. Heat bonded seams -5-  .
   5. 2.5. Remove filler plate.
      Fig 3: Removing Filler Plate (Except Boxster, Boxster S, Boxster GTS)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Cut marked areas →  of the rear end out roughly. Body saw WE 1508 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Remove rear-end rough cut.
5. Remove remaining pieces.
   1. 5.1. Hold flow drill screws -1-  with a pliers and loosen them by tapping with a hammer.
   2. 5.2. The flow drill screw -1-  is pressed into the side member.
   3. 5.3. Drill through punch rivets -2-  using a → Diameter: 6.6 mm  .
      Fig 4: Removing Rear End (Except Boxster, Boxster S, Boxster GTS)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Information 

   Remove flow drill screws from the cavities.

6. Remove flow drill screw from the side member cavity using a bar magnet.
   Fig 5: Removing Flow Drill Screws From Side Member

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Information 

   Drill out the connection point on one side only. Do not damage the plate underneath.

7. Drill out spotwelds.
   Fig 6: Removing Pieces Of Wheel Arch

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Information 

   Drill out the connection point on one side only. Do not damage the plate underneath.

8. Drill out spotwelds.
   Fig 7: Removing Pieces Of Dome

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Information 

   Installation information: Welded seams will be replaced by rivets.

9. Grind off welded seams -1-  .
   1. 9.1. Heat bonding areas -2-  .
   2. 9.2. Remove remaining pieces.

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

10. Heat bonding areas -1-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

11. Heat bonding areas -2-  .
    1. 11.1. Remove remaining pieces.

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.

12. Drill out spotwelds.
    1. 12.1. Remove remaining pieces.

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.