So, I'm in need of a muffler....what are my options?

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Hey everyone,

Reviving this old thread as I just installed the Bosal muffler on my LX and thought this information might be helpful to others.

You can pretty easily find $40 off coupons (I think you had to spend $110 to get the $40 off) from Advance Auto Parts. Moreover, they had free shipping for orders over $100 or so (before the coupon) so I ended up getting the muffler and gaskets for around $100. The price was a little less than Rock Auto as I recall before adding the $40 off.

And here's the kicker, it said that it comes with a lifetime warranty! Nice...

A few other quick tips to anyone who needs to do this repair:

  • As others have said...get extra gaskets to double up if there are any leaks-I also had a leak at the rear cat that was fixed with the double gasket
  • You can totally do this at home (it will suck, it will take way too long) and save your tailpipe/resonator if you have a pneumatic cut-off wheel to grind off what's left of the old bolts - and as others have said the rubber mounts will also need a shaving from the cut-off wheel to fit (I did not trim the muffler brackets or re-weld them, I just modified the rubber/metal mounts)
  • Once you cut out the muffler you'll also be thankful that you bought that air chisel to blow out what's left of the bolts in the tailpipe
  • I had to remove the front muffler bracket from the truck's frame to get the exhaust together - my truck sees little winter use since I've owned it but it's certainly got some rust under there, but both bolts came out - impact certainly helps when doing rusty bolt removal.

Good luck to any who put it on...it otherwise fit really well and seemed like a decent part. Nice to be able to save my resonator too. It's still in good shape and I'm kinda on a budget these days.
 
Ok, another little update.

It appears I blew out one of the gaskets on the Y-pipe :(

Over the last week or so, I noticed the sound or air escaping as I drove past buildings.

Put her up on my left and sure enough it was leaking right where the Y-pipe bolts up :doh:

Ordered up a new set of gaskets including the ones for the cat (since I'll have to unbolt it too)

I figured with my luck, I'll probably snap the studs, so I ordered those as well with new lock nuts and while I had my parts guy on the phone, I also told him to throw in a set of OEM seals so I could compare it to the Bosal stuff....


newexhaustsealsupdate1.jpg

newexhaustsealsupdate2.jpg

newexhaustsealsupdate3.jpg

newexhaustsealsupdate4.jpg


The OEM seals are actually wrapped like they took a long flat piece of steel and just rolled it around a tube a few times, then joined by stamping it together.

The Bosal seal looks as though it was stamped on one side.

Gunna try the the OEM seals this time around and see how long they last
 
Snake, how is the exhaust system itself holding up?
 
Would you do this all over again, or would you go Stock system given the money and time you put into the system. I don't have the tools or access to them like you do. Main question is for a driveway install would you go stock vs the system you got?
 
Would you do this all over again, or would you go Stock system given the money and time you put into the system. I don't have the tools or access to them like you do. Main question is for a driveway install would you go stock vs the system you got?

The stock system is still WAY too expensive, so I'd most likely go this route again if needed :meh:

I would still like to get an OEM muffler, even a used one because I miss the turbo like whistle :redface:

Given the amount of fab work needed to make the Bosal system fit, I wouldn't attempt in my driveway unless there was no other option :doh:
 
Another little update....

Pulled the Y-Pipe to change the seals and decided to yank the secondary cat to check the flow.

Sure as $h!t it was clogged and most likely what caused my temporary power loss on the way home yesterday :doh:

cloggedbosalcat.jpg



Fixed it with a screw driver and a BFH ;)

uncloggedbosalcat.jpg


The primary cat on the Y-Pipe looked fine

Now she's got quite a boost in power :clap:


No MIL (yet), but I've only put her through one drive cycle :meh:

If/when she throws a code, I'll look into getting a high flow cat from MagnaFlow or sumthin :hmm:
 
Glad to see that was the cause and not anything worse!

Is the cat still warrantied?
 
Glad to see that was the cause and not anything worse!

Is the cat still warrantied?


Another update....

About a week later the Y-Pipe seals started leaking again.

Installed new seals and gutted the primary cat as well cause it was a bit on the filthy side.

Got a nice power increase and surprisingly, she never threw a code, so no simulator needed :)

That being said, a few days ago the Y-pipe seals started leaking again.

The inner pipe flange had deteriorated, which caused the seals to keep blowing out, so I picked up a new MagnaFlow Y-pipe

newmagnaflowypipe8.jpg

newmagnaflowypipe9.jpg



So far, so good :cool:
 
Another update....

About a week later the Y-Pipe seals started leaking again.

Installed new seals and gutted the primary cat as well cause it was a bit on the filthy side.

Got a nice power increase and surprisingly, she never threw a code, so no simulator needed :)

That being said, a few days ago the Y-pipe seals started leaking again.

The inner pipe flange had deteriorated, which caused the seals to keep blowing out, so I picked up a new MagnaFlow Y-pipe

newmagnaflowypipe8.jpg

newmagnaflowypipe9.jpg



So far, so good :cool:

Yeah, just wait...that P420 is coming pal!!!

I have a high flow spun wound cat from Magnaflow and the P420 code came on after several cycles. I'm gonna have to do the simulator deal shortly.
 
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