My rear muffler broke at the weld (on the axle pipe side).

I bought a Bosal rear muffler at Napa, somewhat more expensive (62USD)than the Starla you can get from FCP Groton (45USD).

Here are my problems :

1) Part of the rear muffler stuck to the axle pipe
The small part after the weld is stuck to the axle pipe. I started peeling it off using a chisel and a hammer after driving the car when the pipes are still somewhat hot. But I don't see the end of it. How can I remove this? Chisel and hammer technique does not work and my hands are very sore.

2) The S tail end pipe is stuck to the old rear muffler
If possible I'd like to re-use the S tail end pipe. It is not rusted. But the metal has "mated" with the rear muffler. Is there a way of removing it?

I would hate to not finish this job myself and have to take the car to my Volvo indy shop. Almost ready to give up...

Any tips on putting the new rear mufler in once I have solved 1) and 2) are appreciated. I don't have any special tools.

Many thanks Bricksters !
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'89 244DL M47 166K miles

Well I gave up, I did try the metal saw.

My Volvo indy shop could not take me today. So I just stopped at one of the chain muffler and brake shops (M..as) which I dislike so much, just asking them to remove the two bits of stuck metal with a torch. The manager tried to convince me that I should just replace the entire axle pipe and that it was rotted through since the muffler gave in without even looking at the car, and he spoke with authority, "I have been in the business for 20 years, believe me" he told me. I stood firm (the axle pipe is fine, it was replaced two years ago, the muffler broke at the welding) and I asked him how much he would charge me just to remove the two metal bits, seeing that he was not going anywhere with me, he had one if mechanic remove the two metal bits with a torch and charged me still 20 dollars for it. It took him a grand total of 6 minutes. Went back home and put the new Bosal muffler in with the old S tail pipe.

So much easier with a torch !

I did put some liquid soap on the S tailpipe as it was hard to slide it on.

By the way the Boasl seems to fit much better than the International (could not not see any other name on it) that was there before. The International lasted only two years... I hope the Bosal will last longer.

Thanks all for your input.
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'89 244DL M47 166K miles

A Sawsall with a good metal cutting blade works well for making a slit in an internal, male, fitting stuck inside a female fitting and also vice versa. With the Sawsall though you can put the blade inside the whole pipe. Once you make the slit on the inside or outside you should be able to peel or pry the piece off. Autozone lends out an exhaust pipe expander and also sells fittings for you to go from pipe to pipe. Two nights ago I had to fix my exhaust at the same place as My s pipe broke off in the muffler. Both relatively new. I had a hard time getting the peice out of the muffler but then bought a 2" ID to 1 7/8" OD fitting to connect the system back together.

I found an angle grinder with a cutting disc to be effective - it won't help with the tailpipe though as the 'female' section is the bit you want to use again. Maybe with it off the car a bit of twisting will loosen it.

Just a tip - the mufflers generally last longest - the other bits fail along the seams, some of which are on top of the pipe and hard to see from below. Might be worth checking carefully before taking a lot of trouble to save bits.

Thanks Glen.

It is already off the car. But it won't budge... with all the banging, twisting, hammering. I may give up on the S tail pipe. I think they are asking for 15 dollars at Napa for it.
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'89 244DL M47 166K miles

You could try cutting off the muffler level with the tailpipe socket, then cutting down the splits with a hacksaw - this will enable you to pry most of the stuck bit inwards and release it - it's the sealant that holds it solid, which hopefully won't go right to the end of the pipe.

I got a genuine Volvo replacement - the new tailpipe socket had so much clearance I couldn't get it to grip the muffler outlet effectively, and re-used the old one anyway!

I have acetylene torches so it's easy BUT in your case.

1. The Muffler section on the Axle pipe is Over the Axle pipe. You should be able to Hacksaw a slit down the length of the old muffler piece . It should be easy to knock off after that.

2. Same with the 'S' pipe. you will have to hacksaw the old Muffler leaving a small piece of Muffler inside the 'S' pipe. Then use a hacksaw on the inside of the 'S' pipe to cut a slit in the leftover Muffler piece. after it's cut, you should be able to peel it up a bit and slide it out.

The 'S' pipe will be hard to put on the new muffler because the Clamp mis shaped it. You may have to try and open the pipe up. running to a shop and having them use a spreader might be in order. I bought a tool but for this but you may not want to spend the money. A little dishwashing soap may help a lot to lubricate the pipes as you put them together. It washes away after one rain.

It wont be fun.

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'75 Jeep CJ5 345Hp ChevyPwrd, two motorcycles, '85 Pickup: The '89 Volvo is the newest vehicle I own. it wasn't Volvos safety , it was Longevity that sold me

I saw a small torch at Kmart -- I think it is for plumbing. It costs about 15 dollars with one canister.

Will that do? Is that the kind you use?
Can I use a torch on the axle pipe right below the gas tank?

Thanks Tony.

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'89 244DL M47 166K miles

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1&item=7980462838&category=33633&sspagename=WDVW

This is something like the Tool I own to expand the deformed pipe.
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'75 Jeep CJ5 345Hp ChevyPwrd, two motorcycles, '85 Pickup: The '89 Volvo is the newest vehicle I own. it wasn't Volvos safety , it was Longevity that sold me