Stock muffler replacement

[ouroboros314]

I have a 91 accord with a large hole in the stock muffler. The pipes look fine so am only looking to replace the muffler. It looks as if the end attaching to the pipes is secured by a pinch device and all I would need to do to remove the muffler is loosen this pinch, remove the hanging supports, and pull the muffler off, although with 18 years of rust this might not go so easy. I don't have the supplies to start cutting and I don't really know how to make the cutting work in my favor. If you could please give some direction as to how I should resolve this situation I would be most greatful.

[jeffcoslacker]

In the shop we used a chain cutter to lop the muffler off just ahead of the old joint, the new one's inlet is sized to go over the remaining pipe.

You might be able to rent a chain cutter at Autozone or something...works like an oil filter wrench but had a chain of cutting wheels instead of a strap. Takes about 30 seconds to cut one off....

[jeffcoslacker]

It just occurred to me...by "pinch device" do you mean an exhaust clamp?

If so, it's been replaced before.

What you'll have to do is, snap the bolts off the old clamp (just break them off, they aren't gonna be re-used and aren't going to cooperate)

So now you have access to the joint.

Take a sharp chisel, and working from forward to back, split the inlet of the muffler back about 2", at least well past the crimp the clamp left....do this in at least two places around the inlet pipe. Easier if you have a cutoff wheel tool, but sounds like you don't so you'll be chiseling.

Once you've split the pipe, use a blunt chisel against the edge face of the inlet and hammer it rearwards, once it bends out a little wedge the chisel in there and hammer, it'll peel like a banana. Move the muffler around up and down and back and forth to free it. Wd-40 helps a lot. Try not to wrench the pipe ahead any more than you have to, it puts a lotta stress on the old flex pipe and manifold joint farther up the line...really good if you can have someone hold the front pipe still while doing this...

Slide the new muffler over the old pipe, crimp well with a new clamp (get it tight as hell, if the pipe doesn't crimp, it'll leak or the muffler will blow off).

Done. Good luck!

[ouroboros314]

Thanks, I will attempt at replacement. I'll post about success or failure when done.

[mpumas]

I don't normally tell somebody this. But, sometimes it is better to let the professionals do the job. They have the welding equipment that really needs to be used when doing exhaust work. The job is easy for them, therefore not expensive and they will ensure that there are no leaks. A leakey exhaust system can cause fumes in the passenger compartment and corrosion to the underpan. The $40-60 spent will save you in the long run.

[ouroboros314]

If anyone is interested I was able to successfully install a new muffler. The old one was a little pain in the ass at the very end of chiseling. I was able to remove most of the old sleeve which fit over the exhaust pipe except for the last two centimeters or so. I used a hacksaw to cut through the exhaust pipe as close as possible to the muffler in fear of harming the exhaust pipe if I attempted to bang it off with a sledge hammer. With the old one off it was a very easy installation of the new muffler.

Only thing is, there is a small hole in the exhaust pipe that seems to have formed due to a puncture becuase it is not rusted and there is a good amount of jagged metal pushed in. Due to this the car is not 100% quiet and fairly noisey under engine load. It doesn't seem like to big of a problem to me but I don't know how picky the inspections are.

On the positive side I have noticed a nice performance increase and much better idle rpms.

Thanks to everyone who offered suggestions.

[mpumas]

What are you going to do about the hole? I recommend you get it welded. A small hole will become a large hole and be unrepairable if it is surrounded by rust which will be the case in a month or so. Also consider the fumes and possible corrosion to the pan.