Muffler replacement (2025)

[NoVaGator]

This is certainly not a new topic, but I thought I'd share what I learned on my muffler replacement today.

First of all, I bought this muffler from Amazon:

https://www.amazon.com/dp/B09M8Z97DK?tag=ihco-20

It came with the necessary gaskets for the flanges, as well as the output clamp

I bought these bolts: (you'll need 2 packages for 4 bolts)

Amazon.com: 2PCS Car Exhaust Manifold Bolts,Steel M10x1.5 mm Exhaust Bolts and Nuts Kit with Springs for Exhaust Gasket,Professional Exhaust Flange Bolts Car Accessories for Most Cars : Automotive

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www.amazon.com

I bought these exhaust hangars:

https://www.amazon.com/dp/B0BPNSLPX8?tag=ihco-20

Now if you've read any of the other muffler install posts, you'll see absolute nonsense re: soaking bolts in PB Blaster or whatever for a week prior to your uninstall.

Screw all that.

What you're going to do is cut the output clamp off with an angle grinder.

And then you're going to cut the two input pipes at the front of the muffler (very close to the flanges) with an angle grinder or a recip saw.

Then you're going to cut the old rubber exhaust hangers with the angle grinder, or an oscillating tool if you're afraid of bigger tools.

Then you're going to hit the backside of the muffler with a BFH a few time until the muffler launches forward and off of the tail pipe.

All of that that will take about 5 minutes if you do it like you mean it.

With this out of the way, you'll have plenty of space to grind the 4 flange bolts off with either your angle grinder or a die grinder if you're fancy like that. Just go after them with a vengeance on the "waste" side of the flange. You can't hurt anything.

And then it's a very simple job of installing the new muffler, which probably doesn't even warrant discussion.... but I will explain is someone asks

 

[RapidRob]

I've used that muffler, It's a perfect fit and is nearly silent.
Maybe I have less rust than you but I just broke the bolts on the rear clamp and
unbolted the front flanges. definitely a 1 job.

 

[Gartenmeister]

@NoVaGator thanks for the write-up. This kind of thing is very helpful for those of us who are mechanically inclined, slightly motivated but completely inexperienced (me). The links are super helpful too.

 

[Gartenmeister]

So in case anybody is interested I also went ahead and bought the Northeastern exhaust through Amazon.

I made an effort to remove the bolts and got two out clean with an impact wrench but rounded off the others so ended up following OP's procedure to cut and grind everything. My experience was that it was not quite as easy as OP would suggest, definitely took way more than 5 minutes. Be sure to have an angle grinder, discs and PPE before climbing under there.

Anyway here is the muffler that I got because this thread needs pictures. Notably, it did not come with the exit clamp and gasket. I had to cut my clamp off but was able to reuse it. I also had to cut off the guard for the harmonic balancer but they both swapped over easily. I had a tough time getting it in but everything lined up reasonably well.

The unit is quiet compared to my old holy muffler, especially outside the vehicle. The sound is pretty unremarkable so if you're looking for a throaty rumble, this won't do it. Probably pretty close to stock I would guess. I think the draw here is the price, muffler and hardware together were right about $300.

 

[LXfromTX]

Pictures appreciated since I haven't slid under there in some time.

 

[Gartenmeister]

Pictures appreciated since I haven't slid under there in some time.

This is what it looks like under there.

 

[Vthelexus]

So in case anybody is interested I also went ahead and bought the Northeastern exhaust through Amazon.

I made an effort to remove the bolts and got two out clean with an impact wrench but rounded off the others so ended up following OP's procedure to cut and grind everything. My experience was that it was not quite as easy as OP would suggest, definitely took way more than 5 minutes. Be sure to have an angle grinder, discs and PPE before climbing under there.

Anyway here is the muffler that I got because this thread needs pictures. Notably, it did not come with the exit clamp and gasket. I had to cut my clamp off but was able to reuse it. I also had to cut off the guard for the harmonic balancer but they both swapped over easily. I had a tough time getting it in but everything lined up reasonably well.

The unit is quiet compared to my old holy muffler, especially outside the vehicle. The sound is pretty unremarkable so if you're looking for a throaty rumble, this won't do it. Probably pretty close to stock I would guess. I think the draw here is the price, muffler and hardware together were right about $300.

View attachment 4042694View attachment 4042695View attachment 4042696
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I know it's an old thread and I hope you still remember which exit clamp and gasket did you end up buying? Thanks in advance.

 

[Gartenmeister]

I know it's an old thread and I hope you still remember which exit clamp and gasket did you end up buying? Thanks in advance.

I just reused the OEM parts that were on the truck. I had to cut the clamp bolt to get the old muffler off but the rest of the clamp was fine.

 

[Vthelexus]

I just reused the OEM parts that were on the truck. I had to cut the clamp bolt to get the old muffler off but the rest of the clamp was fine.

was there a gasket too?