Muffler Replacement

[junebug76]

I have a 93 Escort LX Wagon with a 1.9L engine. I was wondering if any of you have replaced a muffler on a similar model and if so, how hard is it? Can I do it without a lift? I'm comfortable with things like replacing the oil, changing the headlamp bulbs, you know, simple stuff.

Also, does anyone have any experience, (good or bad) with partsgalaxy.com?

My poor escort... I fear it won't be with me much longer. I live in a state where I have to get it inspected every year, and it's getting harder and harder to pass.

Thanks for any help!

[bigrod118]

well replacing the muffler is real easy...depending on how it is on there. if im not mistaken it comes stock with flanges. so its a matter of getting the back up on stands, getting under there and taking off two bolts holding the muffler onto the pipe and then placeing the new muffler(if stock replacement) onto the pipe and putting the bolts back on. I think if you have a easy time with changeing the oil, you'll figure it out once your under there.

[Sandfobs]

I'm reopening this thread because I have removed the clamp for my muffler and removed the hangers but I can not get the muffler off. I am not sure what to do here I don't want to cut the muffler off as I'm sure there must be a proper method. Any suggestions, Oh I did spray some breakaway around the connection.

[Sandfobs]

Still having problems I can't get in close enough with hacksaw to cut the muffler right off as I've tried everything to get it off but no luck whatsoever. Any help would be great

[01WHTSE]

You have a couple of options to start off with: with everything unclamped I'd first try a using large hammer on what remains of the old muffler after a couple of squirts of something like WD40 where the muffler and exhaust pipe join together. If starts moving give it another squirt and keep tapping. If that doesn't work I'd move on to a chisel and hammer at the same location. You need to be careful that you only cut the outer (muffler) sleeve. Once the sleeve is cut, you can usually separate the two pipes. Good luck.

[Sandfobs]

Yah it's kinda funny I can't remove the muffler off but yet the muffler is falling apart in my hands LOL. I'm resting for the evening but will try again first thing in the morning. What I have done so far is with a hacksaw was cut diagnoly across the outer sleeve and used the hammer to pry the muffler sleeve but it still will not budge. I don't want to damage the pipe that I would like to attach the new muffler too so I'm getting abit frustrated.

I will smash out the old muffler and work that way tomorrow.

[denisond3]

99% of my problems with getting mufflers off was solved when I bought my self an oxy-acetylene torch set. The only thing I have to be careful about is having some metal heat shields, so the torch flame isnt heating up other things, beside the neck of the muffler. Especially when the fuel tank isnt far away, and is made of plastic.
Often I find that if the muffler is falling apart, that intermediate pipe isnt in much better shape! It may come apart when you hammer the muffler off the end of it. Then the problem would be undoing the two bolts that connect the front end of the intermediate pipe to the back end of the catylytic converter on these Escorts - so you can get a new intermediate pipe. Another use for the 'torch'.
I live in VA in the summers, and find that some inspectors are very quick and dont check much. Others will put the car on the lift and tell you if you have rusted brakes lines, or the drivers floor is rusting out. I much prefer the more thorough inspectors.
I would also like to know if partsgalaxy was good to deal with.

[AzTumbleweed]

I have a '93 wagon. I hack sawed mine off. Bought a replacement at AutoZone called a Turbo2 for $20.

[Sandfobs]

Unfortunately if I hacksaw off where the old one is it will be to short to add the new muffler that's why I must remove the old muffler sleve off the intermediate pipe.

I smashed out the old muffler but am still working on removing it from the intermediate pipe.

[AzTumbleweed]

If it's too short you can buy an extension.

[Davescort97]

Can you cut it off with a sharp chisel? You should have gone to the muffler shop. lol. Just kidding. Stay after it you'll git er done.

[Sandfobs]

LOL Dave I contemplated that many times of going to a shop. What I didn't want to do is use an extention and create another joint that could increase more problems and again less performance, I wanted to remove the muffler without damage to the intermediate pipe.

Good news!!!! I did manage to do it. After some thought a hacksaw is just too slow and if I ever wanted to do this again how could I do it quickly and how I did it was this:

I used my drill with a metal cutting disc (or anyone could use dremolo) and pulled the muffler the furthest I could towards the back of vehicle and used the cutting disc to edge a straight line from the end of the muffler sleeve straight back right and cutting right into the muffler itself. I then used a small chisel and hammer and being careful not to damage the intermediate pipe hammered into the cut and pryed the sleeve away from the intermeidate pipe then used a hammer and hit the muffler towards the back of the vehicle and once the joint released it slid almost right out, a couple more bangs with the hammer and it came out.

I then sanded and smoothed the intermediate pipe and washed it with soap and water and dried. I then applied muffler cement to intermediate pipe and also inside the female on the muffler. I slid the muffler on and re-installed the hangers, aligned the muffler straight and then tightened the clamp. I have let the engine run for 5 minutes to cure the muffler cement and let it sit for a half hour.

I hope this helps someone, my PAIN of removing this muffler I just don't want anyone to not know this short cut.