Date:         Sun, 11 Jan 2004 22:18:10 -0500
Reply-To:     Jon Schaer <jschaer@COLUMBUS.RR.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Jon Schaer <jschaer@COLUMBUS.RR.COM>
Subject:      Re: Replacing Muffler
Comments: To: tabe johnson <xtabe@YAHOO.COM>
Content-Type: text/plain; charset="iso-8859-1"

----- Original Message -----
From: "tabe johnson" <xtabe@YAHOO.COM>
>
> My muffler is on the way out, as is the pipe just in front of
> the catalytic converter. Anything special I need to know?
>

my observations.....only done it once.

Old nuts/bolts were a major, massive, unbelievable PIA to remove, but I
didn't have a torch to just cut 'em off. Use stainless to reassemble, and
include lockwashers.

Use exhaust gasket puckey along with the regular gaskets.

Probably obvious, but do ox sensor removal/install of the vehicle.

Assemble the entire sheebang and install as a unit (Y-pipe, cat, muffler).
Makes access to nuts/bolts better (especially at cat - mine had these three
support straps from the flange to the body, making fastener access lousy).

To minimize stress on both downpipes, don't just attach the system and then
cinch up the support strap at the muffler. This might put a preload on the
older downpipes. Support the sheebang with a jack or something and bolt up.
Assuming the position is good and clear, loosen the support rods/strap and
make it readjust to the position of the sheebang as best you can, then
tighten up. Loosen the bolts at downpipe flanges a little to modify sheebang
position (if needed) and release any downpipe preload, then retighten.

Anyone have muffler comments? I installed an Ansa, and it has seemed louder
than what was on previously (@125,000 miles, so I doubt original).

Jon Schaer
Columbus, OH
1985 GL
139,000