How to Replace a muffler..

archebald23

Banned
Jun 24, 2010
5
0
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hi there.anyone among you who knows how to change or how to replace a muffler?thanks!

You already knew the Garage subforum existed since you've been necro-ing threads here for two months now. I don't know why you left this thread in OT, but I'm putting it in the Garage where it belongs.

Zenmervolt - AnandTech Moderator
 
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Squisher

Lifer
Aug 17, 2000
21,204
66
91
We have a forum called The Garage and this is right up their alley. However, let me say exhaust systems were the first job that I turned over to people who have car lifts, air chisels, and cutting torches and that would be some 30 years ago.

Beating on a splitting chisel with a hammer under a car with all the rust and dirt falling down on you is no fun and can be hard on your knuckles.
 
Oct 27, 2007
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Beating on a splitting chisel with a hammer under a car with all the rust and dirt falling down on you is no fun and can be hard on your knuckles.
:confused: Use a fucking pipe cutter. Takes 10 minutes, almost no mess.

gr18612.jpg
 

TridenT

Lifer
Sep 4, 2006
16,800
45
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Replacing a muffler is so easy that I did it on my 2000 Honda Civic with no problems... Easy-easy-easy
 

Mike Gayner

Diamond Member
Jan 5, 2007
6,175
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:hmm:

What the Haynes manual says vs what it should say said:
Haynes: Rotate anticlockwise.
Translation: Clamp with mole grips (or an adjustable spanner) then beat repeatedly with hammer anticlockwise. You do know which way is anticlockwise, don't you?

Haynes: Should remove easily.
Translation: Will be corroded into place ... clamp with mole grips then beat repeatedly with a hammer.

Haynes: Remove small retaining clip.
Translation: Take off 15 years of stubborn crud, it's there somewhere.

Haynes: This is a snug fit.
Translation: You will skin your knuckles! ... Clamp with mole grips then beat repeatedly with hammer.

Haynes: This is a tight fit.
Translation: Not a hope in hell matey! ... Clamp with mole grips then beat repeatedly with hammer.

Haynes: As described in Chapter 7...
Translation: That'll teach you not to read through before you start, now you are looking at scary photos of the inside of a gearbox.

Haynes: Locate ...
Translation: This photo of a hex nut is the only clue we're giving you.

Haynes: Pry...
Translation: Hammer a screwdriver into...

Haynes: Undo...
Translation: Go buy a tin of WD40 (catering size).

Haynes: Ease ...
Translation: Apply superhuman strength to ...

Haynes: Retain tiny spring...
Translation: "Jeez what was that, it nearly had my eye out"!

Haynes: Press and rotate to remove bulb...
Translation: OK - that's the glass bit off, now fetch some good pliers to dig out the bayonet part and remaining glass shards.

Haynes: Lightly...
Translation: Start off lightly and build up till the veins on your forehead are throbbing then re-check the manual because what you are doing now cannot be considered "lightly".

Haynes: Weekly checks...
Translation: If it isn't broken don't fix it!

Haynes: Routine maintenance...
Translation: If it isn't broken... it's about to be!

Haynes: One spanner rating (simple).
Translation: Your Mum could do this... so how did you manage to botch it up?

Haynes: Two spanner rating.
Translation: Now you may think that you can do this because two is a low, tiny, ikkle number... but you also thought that the wiring diagram was a map of the Tokyo underground (in fact that would have been more use to you).

Haynes: Three spanner rating (intermediate).
Translation 1: Make sure you won't need your car for a couple of days and that your AA cover includes Home Start.
Translation 2: But Novas are easy to maintain right... right? So you think three Nova spanners has got to be like a 'regular car' two spanner job.

Haynes: Four spanner rating.
Translation: You are seriously considering this aren't you, you pleb!

Haynes: Five spanner rating (expert).
Translation 1: OK - but don't expect us to ride it afterwards!!!
Translation 2: Don't ever carry your loved ones in it again and don't mention it to your insurance company.

Haynes: If not, you can fabricate your own special tool like this...
Translation: Hahahahahahahahahahahahahahahahahahahahahahaha!!!!

Haynes: Compress...
Translation: Squeeze with all your might, jump up and down on, swear at, throw at the garage wall, then search for it in the dark corner of the garage whilst muttering "ah heck" repeatedly under your breath.

Haynes: Inspect...
Translation: Squint at really hard and pretend you know what you are looking at, then declare in a loud knowing voice to your wife "Yep, as I thought, it's going to need a new one"!

Haynes: Carefully...
Translation: You are about to cut yourself!

Haynes: Retaining nut...
Translation: Yes, that's it, that big spherical blob of rust.

Haynes: Get an assistant...
Translation: Prepare to humiliate yourself in front of someone you know.

Haynes: Turning the engine will be easier with the spark plugs removed.
Translation: However, starting the engine afterwards will be much harder. Once that sinking feeling in the pit of your stomach has subsided, you can start to feel deeply ashamed as you gingerly refit the spark plugs.

Haynes: Refitting is the reverse sequence to removal.
Translation: But you swear in different places.

Haynes: Locate securing bolt.
Translation: Remember that worrying noise when you drove along the A38 last summer? That's where you'll find the securing bolt.

Haynes: Prise away plastic locating pegs...
Translation: Snap off...

Haynes: Remove drum retaining pin.
Translation: Break every screwdriver in your box.

Haynes: Using a suitable drift or pin-punch...
Translation: The biggest nail in your tool box isn't a suitable drift!

Haynes: Everyday toolkit
Translation: Ensure you have an RAC Card & Mobile Phone

Haynes: Apply moderate heat...
Translation 1: Placing your mouth near it and huffing isn't moderate heat.
Translation 2: Heat up until glowing red, if it still doesn't come undone use a hacksaw.
Translation 3: Unless you have a blast furnace, don't bother. Clamp with mole grips then beat repeatedly with hammer.

Haynes: Index
Translation: List of all the things in the book bar the thing you want to do.

Haynes: Remove oil filter using an oil filter chain wrench or length of bicycle chain.
Translation: Stick a screwdriver through it and beat handle repeatedly with a hammer.

Haynes: Replace old gasket with a new one.
Translation: I know I've got a tube of Krazy Glue around here somewhere.

Haynes: Grease well before refitting.
Translation: Spend an hour searching for your tub of grease before chancing upon a bottle of washing-up liquid. Wipe some congealed washing up liquid from the dispenser nozzle and use that since it's got a similar texture and will probably get you to Halfords to buy some Castrol grease.

Haynes: See illustration for details
Translation: None of the illustrations notes will match the pictured exploded, numbered parts. The unit illustrated is from a previous or variant model. The actual location of the unit is never given.

Haynes: Drain off all fluids before removing cap.
Translation: Visit bathroom, spit on ground, remove baseball cap in order to scratch head in perplexity.

Haynes: Top up fluids.
Translation: Drink 2 cans of beer and call out a mobile mechanic to undo the damage.


And now to look at some of the basic tools required...

HAMMER: Originally employed as a weapon of war, the hammer is nowadays used as a kind of divining rod to locate expensive parts not far from the object we are trying to hit.

MECHANIC'S KNIFE: Used to open and slice through the contents of cardboard cartons delivered to your front door; works particularly well on boxes containing seats and motorcycle jackets.

ELECTRIC HAND DRILL: Normally used for spinning steel Pop rivets in their holes until you die of old age, but it also works great for drilling mounting holes just above the brake line that goes to the rear wheel.

PLIERS: Used to round off bolt heads.

HACKSAW: One of a family of cutting tools built on the Ouija board principle. It transforms human energy into a crooked, unpredictable motion, and the more you attempt to influence its course, the more dismal your future becomes.

MOLE-GRIPS/ADJUSTABLE SPANNER: Used to round off bolt heads. If nothing else is available, they can also be used to transfer intense welding heat to the palm of your hand.

OXYACETYLENE TORCH: Used almost entirely for lighting various flammable objects in your garage on fire. Also handy for igniting the grease inside a brake-drum you're trying to get the bearing race out of.

IMPERIAL A/F SOCKETS: Once used for working on older cars and motorcycles, they are now used mainly for impersonating that 13mm or 19mm socket you've been searching for for the last 15 minutes.

PILLAR DRILL: A tall upright machine useful for suddenly snatching flat metal bar stock out of your hands so that it smacks you in the chest and flings your beer across the room, splattering it against that freshly painted part you were drying.

WIRE WHEEL: Cleans rust off old bolts and then throws them somewhere under the workbench with the speed of light. Also removes fingerprint whorls and hard-earned guitar calluses in about the time it takes you to say, "F...."

HYDRAULIC FLOOR JACK: Used for lowering car to the ground after you have installed your new front disk brake setup, trapping the jack handle firmly under the front wing.

EIGHT-FOOT LONG DOUGLAS FIR 2X4: Used for levering a car upward off a hydraulic jack.

TWEEZERS: A tool for removing wood splinters.

PHONE: Tool for calling your neighbour to see if he has another hydraulic floor jack.

SNAP-ON GASKET SCRAPER: Theoretically useful as a sandwich tool for spreading mayonnaise; used mainly for getting dog-doo off your boot.

BOLT AND STUD EXTRACTOR: A tool that snaps off in bolt holes and is ten times harder than any known drill bit.

TIMING LIGHT: A stroboscopic instrument for illuminating grease build-up.

TWO-TON HYDRAULIC ENGINE HOIST: A handy tool for testing the tensile strength of ground straps and brake lines you may have forgotten to disconnect.

CRAFTSMAN 1/2 x 16-INCH SCREWDRIVER: A large motor mount prying tool that inexplicably has an accurately machined screwdriver tip on the end without the handle.

BATTERY ELECTROLYTE TESTER: A handy tool for transferring sulphuric acid from a car battery to the inside of your toolbox after determining that your battery is dead as a doornail, just as you thought.

TIN SNIPS: See hacksaw.

POZIDRIVE SCREWDRIVER: Normally used to stab the lids of old-style paper-and-tin oil cans and splash oil on your shirt; can also be used, as the name implies, to round off Pozidrive screw heads.

AIR COMPRESSOR: A machine that takes energy produced in a fossil-fuel burning power plant 200 miles away and transforms it into compressed air that travels by hose to a pneumatic impact wrench that grips rusty bolts last tightened 30 years ago by someone in Dagenham, and rounds them off.

CROW BAR: A tool used to crumple the metal surrounding that clip or bracket you needed to remove in order to replace a 50p part.

HOSE CUTTER: A tool used to cut hoses 1/2 inch too short.

INSPECTION LIGHT: The mechanic's own tanning booth. Sometimes called a drop light, it is a good source of vitamin D, "the sunshine vitamin," which is not otherwise found under cars at night. Health benefits aside, its main purpose is to consume 40-watt light bulbs at about the same rate as 105-mm howitzer shells during the Battle of the Bulge. More often dark than light, its name is somewhat misleading.
 

Squisher

Lifer
Aug 17, 2000
21,204
66
91
:confused: Use a fucking pipe cutter. Takes 10 minutes, almost no mess.

OK, now you've cut off the pipe that slid over the smaller pipe, you still have the remnants of the larger pipe rust welded over the pipe you want to preserve. The only way to get it off is with a splitting chisel.

EDIT: most shops won't even bother with this. They'll just cut off everything and sell you all new.
 
Last edited:
Oct 27, 2007
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OK, now you've cut off the pipe that slid over the smaller pipe, you still have the remnants of the larger pipe rust welded over the pipe you want to preserve. The only way to get it of is with a splitting chisel.
What in the fuck are you talking about? Cut the pipe, clean with wire brush, butt new pipe against it (use a larger pipe if you're paranoid about the weld breaking) and weld them together. Piece of piss.
 

TridenT

Lifer
Sep 4, 2006
16,800
45
91
Have you ever repaired a car in your life?

Repaired? Idk what that would entail, but I have replaced my muffler before... Old one had quite a few holes in it and was loud... Replaced it with a similar version the car came with which is nice and quiet.
 

Squisher

Lifer
Aug 17, 2000
21,204
66
91
What in the fuck are you talking about? Cut the pipe, clean with wire brush, butt new pipe against it (use a larger pipe if you're paranoid about the weld breaking) and weld them together. Piece of piss.

You think this guy has a welder when he doesn't even know how to change a muffler? I guess you've never seen a muffler clamp.
 

Mike Gayner

Diamond Member
Jan 5, 2007
6,175
3
0
You think this guy has a welder when he doesn't even know how to change a muffler? I guess you've never seen a muffler clamp.

Technically speaking the OP wasn't asking for DIY instructions - he's just asking if anyone knows how.
 
Oct 27, 2007
17,009
1
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You think this guy has a welder when he doesn't even know how to change a muffler? I guess you've never seen a muffler clamp.
I wouldn't recommend using those clamps. Eventually they will wear from the constant expansion/contraction (occurring at a different rate to the pipe itself) and will begin leaking. Good for a quick fix, but you should get it done properly when you can.

Oxy welders can be rented, if the OP wants a nice little weekend DIY project then learning to weld and then doing this repair can be achieved in a weekend. Just be careful with that torch around the fuel tank/lines.
 

Squisher

Lifer
Aug 17, 2000
21,204
66
91
I wouldn't recommend using those clamps. Eventually they will wear from the constant expansion/contraction (occurring at a different rate to the pipe itself) and will begin leaking. Good for a quick fix, but you should get it done properly when you can.

Oxy welders can be rented, if the OP wants a nice little weekend DIY project then learning to weld and then doing this repair can be achieved in a weekend. Just be careful with that torch around the fuel tank/lines.
Let me get this straight, you want him to blind torch weld when he gets to the top of the pipes between the pipe and the floor pan and torch weld upside down on the bottoms of the pipe as his first project? If he doesn't come away with third degree burns or sets his car on fire might I suggest he affix a sign on the back of the car that alerts people to the possibility of large metal debris falling out when he gets going 70 miles an hour down the motorway.
 
Oct 27, 2007
17,009
1
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Let me get this straight, you want him to blind torch weld when he gets to the top of the pipes between the pipe and the floor pan and torch weld upside down on the bottoms of the pipe as his first project? If he doesn't come away with third degree burns or sets his car on fire might I suggest he affix a sign on the back of the car that alerts people to the possibility of large metal debris falling out when he gets going 70 miles an hour down the motorway.
Ugh, no. You raise the car as high as your stands will go and drop the exhaust off the hangers.
 

Wheezer

Diamond Member
Nov 2, 1999
6,731
1
81
cut the old one off with a grinder, put the new one one with the proper clamps and pipes.
 

PottedMeat

Lifer
Apr 17, 2002
12,363
475
126
Yes and no. It makes a small difference on what vehicle you're talking about. :)

yep

could be cut off & weld or something like


1. remove 2 bolts on flange attaching muffler to rest of exhaust
2. slide off 2 rubber muffler hangers
3. muffler drops off, install new muffler in reverse order.

88 corolla. took me ~1/2 hour to an hour. i think the hardest part was picking the right muffler online, there were so many listed for the vehicle.
 

StageLeft

No Lifer
Sep 29, 2000
70,150
5
0
I've not done this before but when under my van recently it seemed like the entire exhaust was coated in salt from the factory. It's rusted *TO HELL*. I cannot imagine any of the bolts there are worth a sh*t anymore, hence presumably why people are talking about the more realistic cutting and welding. Otherwise, it's probably quite easy and quick to do.