Can I replace my own muffler? ('94 SL1)

[kurtr]

Is replacing a loud, rusting muffler a do-it-yourself project? Would there be any welding involved?

I've long assumed that I'd need to go to one of these chain muffler shops and get ripped off. Now I'm wondering if this is a job I can do myself.

THANKS!

[sierrap615]

you can do it, but it would be easyier to have some one else do it. clamping works fine, but personially i prefer a weld, for a better seal, more dependible, and a cleaner look.

you will need -
muffler, OEM or universal, 1-7/8 diameter in and out IIRC
tailpipe/downpipe
2 exhaust clamps
i also recommend a new muffler strap, get it from a saturn dealership( universal straps are commonly to weak)
tools: saw, wrenches and/or ratchet/sockets, you may also need a exhaust pipe expander.


use a hacksaw or electric saw to cut the old muffler off, remove muffler strap. besure to leave enought pipe to clamp the muffler to.
check the fit of the new muffer to the pipe, use the expander if needed, in the slim chance the pipe is not 1 - 7/8, you should be able to buy adapter(may need a extra clamp).
bolt the new strap in place
place the clamp loosely on the muffler or pipe, which ever is easier, then slide the muffler into the pipe. attach the strap, then tighten down the clamp.
check fit of tailpipe, use expander if need, then clamp to muffler just as you did with the muffler to exhaust piping.

[bwright138]

I had a similar problem with an old car of mine. What I did was I found a cheap replacement muffler at schuck's ($20) and went and had it welded on by a muffler shop ($40). A little pricier, but to me it was worth the peace of mind.

[kurtr]

Originally Posted by sierrap615

you can do it, but it would be easier to have some one else do it.

Thank you, sierrap615, for this detailed information. Turns out, in my case, it cost just as much to have a local shop do it. I bought (and returned) the muffler strap from Saturn -- $36.65. Pep Boys quoted about $70 for the muffler.

Today I had a muffler shop do the whole job for $116.

(Chicago folks: Budget Muffler & Brake in Addison is highly recommended.)