On my way into work this morning my non-sporty 245 suddenly got LOUDER. I pulled over to investigate and it looks like my rear muffler became disconnected in the front of it. There was some corrosion evident, but nothing looked really rotted out. Since I was in my nice work clothes I didn't crawl around much under there, so I'll look in more detail this evening. Here's my questions:

1. How is the muffler attached, just an exhaust clamp?

2. Can it usually be re-attached?

3. If I need a new muffler system, should I go ahead and get the IPD sport exhaust?

4. How difficult is it to put on an IPD exhaust system myself?

5. What tools would I need?

6. How much crud will I get in my eyes?

> 1. How is the muffler attached, just an exhaust clamp?

Exhaust clamps to incoming and outgoing pipes, an hanging from rubbers.

> 2. Can it usually be re-attached?

If it just popped loose (unlikely), yes. If it broke off, probably. If it rusted off, no because you won't have anything strong to weld it to.

> 3. If I need a new muffler system, should I go ahead and get the IPD

> sport exhaust?

I'll leave this one to the disciples. Personally I just put a good quality box on (Volvo, Bosal, whatever I can get a good price on, not stuff like Walker that's made out of too thin metal and ends to rust through in half the time).

> 4. How difficult is it to put on an IPD exhaust system myself?

I'ld expect it to be no more difficult that putting on an OEM type exhaust.

> 5. What tools would I need?

Depends how much patience you have. I tend to go for judicious application of an angle grinder, cold chisel and 2 or 3 pound hammer, followed by a pry bar and old large flathead screwdriver. Alternatively you could use a gas welding rig. You'll also need the appropriate size spanners or sockets to tighten the clamps on the new exhaust system.

> 6. How much crud will I get in my eyes?

Depends on how dirty and rusty the old system is. I usually wear protective goggles for this kind of work. Expect both dirt and rust flakes to come down.

Bram

I went out to the car at lunch to examine the muffler (boy is it hot outside!). It looks like the smaller diameter pipe that sticks out of the muffler is still intact (the clamp is still there too), but it looks like the larger diameter pipe that gets clamped onto the muffler rusted and broke off. Tonight I'll try to get the clamp off and see if the remaining portion of the pipe can be pushed back onto the muffler and attached again.

Tom,

First of all, due to diameter issues the pipe probably won't be reattachable. Doing that would put a very high stress bon the exhaust system anyway and would likely lead to further breakage in the near future. That pipe's pretty cheap, so you'ld be better off doing a proper replacement. Getting the old pipe out can be a royal pain in the anterior.

I usually take an angle grinder, grind through the clamps, carefully (!) grind through the outer pipe (which is to be discarded anyway) and use a pry bar and lump hammer (or air chisel if available) to open up the remaining bits; they then fall off easily. Can't remember if the pipe is inner or outer where it joins the front muffler, if it's outer then grind as well, if it's inner you'll need to bend open the "sections" (where it's cut in a bit) of the damper pipe and slide it out.

These tasks require a delicate combination of gentle persuasion so as not to break the mufflers and brute force to get the [censored] old bits off.

Bram

Tom, That pipe probably won't be able to be reattached.If it's the over-axle pipe, it's only $12 at V.I.P..Mine rusted off at the same place,the hardest part was undoing the pipe from the front muffler.I ended up using a hacksaw and some big needle nose plyers. Spray every bolt with PB Blaster and get the pipe and 2 new clamps and you'll be quiet as before.

Oh yea, don't work under the car on it's jack, get some ramps while your at the parts place.

Good luck, Phil

Tom, try aa adapter piece from auto store with good selection. Pipe too pipe adapter and too clamps

Tom, a pipe to pipe adapter and two clamps $4. and a bunch of elbow grease, i cut mine off with a cutoff tool.Install with anti-seize for the next time. Bob

Thanks Phil, I'll check it out tonight and see if I can get the pipe, PB Blaster, ramps, and clamps from the parts store. I'll check out the rest of the exhaust system and see if it would make sense to just go ahead and replace everything from the CAT back.