Look for a flat area to ensure the vehicle remains stable while being jacked up. Blacktop or concrete are the preferred surfaces to park your vehicle on.
Disconnecting the battery will ensure the vehicle can’t be started while you work on it. The negative terminal can be identified by looking for the letters “NEG” or the negative symbol (-) around the terminal.
Once the vehicle is high enough to work beneath, place jack stands beneath the vehicle to support its weight. Never work beneath a vehicle supported only by a jack.
You may need to use multiple applications of rust penetrator before you can loosen the bolts. You can purchase rust penetrator at most auto parts or large retail stores.
If you intend to reuse the muffler clamp, you may want to spray it with more rust penetrator as you work it loose. If you break the muffler clamp, you can purchase replacement clamps at your local auto parts store.
If the pipes are too rusted together to come apart, you may have to cut the pipes apart. If your muffler was welded in place, you will have to cut the pipes apart.
Goggle style eye protection is best for this type of job. They will prevent debris from falling into your eyes from above, below and on the sides. Leather workman’s gloves can protect your hands from metal slivers and accidental cuts.
An exhaust cutting tool works in a more confined space that you can often reach with a hacksaw. You can purchase an exhaust cutter at your local auto parts store.
Make sure to keep your eye protection on throughout this process, otherwise you could get a metal sliver in your eye. Make sure to use a hack saw blade rated for steel. You should not need to use multiple blades to get through the exhaust piping.
Attempt to move anything to the side that interferes with your clearance when sawing through the exhaust piping. You may have to saw through a different portion and purchase more pipe to extend the reach of the new muffler if you can’t saw through the pipe without damaging other things.
The end of the piece of metal that goes through the eyelet has a larger diameter than the rest, so you will need to pull hard to get it out. If you tear the rubber eyelet, you can purchase a replacement one at most auto parts stores.
If the pipe from the muffler doesn’t reach the old pipe or fit, you will need to purchase piping or an adaptor from your local auto parts store. If you use an extension pipe, secure it to the muffler’s pipe in the same manner you would secure the muffler pipe to the exhaust.
There should still be enough play in the rubber eyelet to allow you to move the muffler around as you secure it to the exhaust piping. Make sure to replace the rubber eyelet if you damaged it removing the old muffler.
Depending on the brand, you may need to allow the exhaust sealant to sit for a few minutes before moving on. Refer to the instructions on the exhaust sealant to know how long to let it cure. You can purchase exhaust sealant at your local auto parts store.
Most exhaust piping comes in two or two-and-a-half-inch diameters. You will not be able to seal the wrong size pipe onto another pipe, even if you overtighten the muffler clamps.
You may want to use a half inch drive wrench to tighten the clamps to ensure you have enough leverage to tighten it sufficiently. Be sure you tighten the clamp over where the piping overlaps, otherwise you could crush the exhaust piping.
If you are unsure about whether there may be a leak, ask a friend to press down on the gas pedal slightly to increase the RPMs of the engine. This will make leaks more apparent. If you identify a leak, allow the piping to cool off and try to assess its cause. You may need to remove the muffler clamp and seat the two pipes together properly before re-tightening the clamp.
