Time for a new muffler

My OEM muffler finally gave up and got a nice big hole in it. It looks pretty straightforward to replace and I want to go with the OEM part... that muffler comes as a unit with the tailpipe and mid pipe. Is that thing hard to finangle over the axle without taking too much stuff apart? I would also replace the bolts, springs and gasket that attaches the mid pipe to the y-pipe... have you guys had decent luck with that flange taking in the new bolts OK? Mine looks to be in decent shape but somewhat rusty. I haven't sprayed them yet or tried to loosen them.

 

I removed mine recently. If you drop your spare and get a jack to support the muffler while you're undoing everything, it's not too bad to maneuver over the axle and out from under the truck.

The most difficult part was getting the rubber bushings over the lip on the hangers. I've read that using some soapy water helps get them out easier. I used some quick release clamps to force them to go over the lips.

I didn't replace the fasteners, but everything bolted back up just fine. That being said, this is a Southern California truck with zero rust. If worse comes to worst, you could drill them out and put a lock nut on the other side. I imagine that might be a little more work than just drilling them out though.

 

I could always cut the pipes off the old muffler with my angle grinder and cut off wheel which would make removal easier.... but that won't help slipping the new one in. And this thing being a unit is a long unwieldy beast.

It's been awhile since I did an exhaust and you reminded me about those rubber hangers. They can be a bear, especially when pushing one out seems to drive another on tighter. I normally could work this all out even if I got stuck and needed to cut off the old bolts and find some locknuts... except I am "garage poor" and my other car (Corvette) doesn't come out of the one-car garage in the winter unless we get a decent dry period with no snow and salt.... and that isn't right now, still melting off last week's storm. If I got stuck before finishing the muffler and needed to drive it and we have a snow storm I'd be in real difficulty. Maybe I'll put this off till spring. We'll see...

 

If things are rusted up.....don't mess about use a gas flame axe to cut the bolts. Replace with new fasteners.

 

Definitely will use new bolts... the issue is whether or not the flange threads are still good. The pipes themselves look fine. But the muffler and the bolts are done. I could probably save some $$ by cutting the old muffler off from the tailpipe and mid pipe and clamping in a new one instead of getting a new factory muffler/pipe assembly. Have to look at the pipe diameters and such.

 

Perfect time to upgrade to a stainless steel cat-back system!

 

These are great for pulling the old rubber hangers:

 

Cherry bomb glass pack !