Removing rusty mufflers?
Thread Starter
Pro
Joined: Sep 2004
Posts: 690
Likes: 0
From: Madison WI
Removing rusty mufflers?
Okay, so I just received my new pair of Dynomax mufflers and am currently trying to remove the old ones. Problem is, they're obviously rusty and are pretty much stuck on the old exhaust pipe from a combination of rust, dirt, and time. What can I do to remove them? Need help ASAP 
Safety Car
Joined: Aug 2001
Posts: 4,883
Likes: 11
From: North Easton Mass
Originally Posted by 72Tornado
Okay, so I just received my new pair of Dynomax mufflers and am currently trying to remove the old ones. Problem is, they're obviously rusty and are pretty much stuck on the old exhaust pipe from a combination of rust, dirt, and time. What can I do to remove them? Need help ASAP
You will probably need a tailpipe expander to somewhat even out the aread crushed in by the clamp. Expanders can be rented at AutoZone. Beware that if the old muffler is very rusty the pipe it is attached to may be very weak at the joint and it may disintegrate when you try to take off the muffler. It is usually difficult to get a leak-free seal between a new muffler and an old pipe so you may need to slather on some muffler sealer on the pipe when assembling.
Oh yeah, wear safety glasses when doing this job. You'll be taking a rust bath while taking off the old muffler.
Rick B.
Thread Starter
Pro
Joined: Sep 2004
Posts: 690
Likes: 0
From: Madison WI
Originally Posted by Blair Winch Project
You can saw off the old muffler so that just the attachment pipe is left. Then carefully cut lengthwise without cutting into the pipe that you are going to retain. You should be able to gently spread the old pipe with a hammer and screwdriver to loosen it. Of course you can just hack off the old clamp also.
You will probably need a tailpipe expander to somewhat even out the aread crushed in by the clamp. Expanders can be rented at AutoZone. Beware that if the old muffler is very rusty the pipe it is attached to may be very weak at the joint and it may disintegrate when you try to take off the muffler. It is usually difficult to get a leak-free seal between a new muffler and an old pipe so you may need to slather on some muffler sealer on the pipe when assembling.
Oh yeah, wear safety glasses when doing this job. You'll be taking a rust bath while taking off the old muffler.
Rick B.
You will probably need a tailpipe expander to somewhat even out the aread crushed in by the clamp. Expanders can be rented at AutoZone. Beware that if the old muffler is very rusty the pipe it is attached to may be very weak at the joint and it may disintegrate when you try to take off the muffler. It is usually difficult to get a leak-free seal between a new muffler and an old pipe so you may need to slather on some muffler sealer on the pipe when assembling.
Oh yeah, wear safety glasses when doing this job. You'll be taking a rust bath while taking off the old muffler.
Rick B.
Le Mans Master
Joined: Oct 2004
Posts: 5,269
Likes: 54
From: Orlando Florida
St. Jude Donor '05
Use a Dremel (or similar tool) and cut the pipe lenghtwise as suggested above. Spread the outer pipe (the pipe that is welded to the muffler) and spray some penetrating oil in there... it will come off...
The exhaust pipe clamp leaves a groove around the circumference of both pipes, you'll likely see that you can rotate the muffler pipe but cannot pull it off ... spread it some more if needed...
The exhaust pipe clamp leaves a groove around the circumference of both pipes, you'll likely see that you can rotate the muffler pipe but cannot pull it off ... spread it some more if needed...
