Rear muffler trying to break free... how easy it is to replace?

rowan194 · 19-04-2013, 09:47 PM

Noticed yesterday a bit of banging when going over a hump, figured it was something in the boot, then tonight saw my tail pipe was seriously sagging.

Looks like I can get a complete rear muffler assembly on ebay, but how difficult is it to fit? Can't seem to find any exhaust related HOWTOs on the site. I have a Gregory's manual but it's pretty vague. Any tips appreciated, bearing in mind this is probably the original nearly 11 years old exhaust.

edit: 2002 AUIII Fairmont, standard suspension I believe.

XRGhia · 19-04-2013, 09:56 PM

IMO, I'd just buy a new catback... If it is the original exhaust, I'd just swap the catback out at the same time. Can be had from $170+ on ebay...

rowan194 · 19-04-2013, 10:14 PM

Something like this?

http://www.ebay.com.au/itm/STANDARD-...ts_Accessories

What sort of problems am I likely to run into when removing such an old exhaust system?

And just out of interest, is it easy to see if the muffler was blocked once I remove it? I've had something wrong with the exhaust for a while, and have recently noticed that the engine note has changed back to the way it used to be... possibly because of that nice rip in the pipe letting the exhaust get out!

XRGhia · 19-04-2013, 10:19 PM

That'll do the job fine. FYI, Tuff Car Parts are a Forum Sponsor, so hit Justin (Private9) up for a forum members discount

Probably just the front bolts being tight and rusty (use 6 sided sockets/spanners, and some freeze and release) and the hangers (3 of them) being old and cracked..

Crazy Dazz · 20-04-2013, 02:15 AM

Like any exhaust change, it can be a **** of a job. The most difficult thing is removing that section of exhaust where it joins onto the central muffler. If it is rusted solid then its an angle grinder job.
The biggest shitter can be when, after finally getting the ****** off, you discover that its not standard diameter.
I tend to agree with XRGW. Check your whole exhaust carefully, and if the main muffler is also on the way out, change it all from the cat back. It is two very easy bolts to remove and a gasket, then you can hack the rest into pieces.
The only other challenging bit can be that last hanger you can see in your first photo. You need to push the exhaust up and squash the rubber, so you can pull it off the flat hook. (Forget trying to pull the hanger out of the rubber. They LOOK like they should come out easy but don’t.)

If buying off eBay, be careful you get the right one. Fairmonts have that extra muffler at the end, but my other AU’s did not. (Could just be cheapo after market jobs?)

XRGhia · 20-04-2013, 02:18 AM

All cars should have a muffler and/or resonator on the rear to be legal. I'd say someone just did a quick cut and shut to remove a rusty muffler...

rowan194 · 20-04-2013, 09:35 AM

Quote:

Originally Posted by xrghiawagon

All cars should have a muffler and/or resonator on the rear to be legal. I'd say someone just did a quick cut and shut to remove a rusty muffler...

How does something like this work, then? Seems to have all the right sections, but it's missing the resonator and rear muffler.

http://www.ebay.com.au/itm/2-5-CAT-B...ts_Accessories

Wondering what I should do in the meantime, tie up the muffler with some wire (but risk the pipe breaking completely), or just leverage the whole thing off? Or not drive the car at all?

FGII-XR6 · 20-04-2013, 09:44 AM

as said above get a new cat back system, once they get to this stage you can repair it but you'll keep repairing it as other sections break.
you can go standard as mentioned above but for a bit extra you can get a 2.5" redback system that will sound better and perform better
http://www.ebay.com.au/itm/REDBACK-2...item27b43a6983
as mentioned ask him for a forum discount

**Whoosha** · 20-04-2013, 10:32 AM

Quote:

Originally Posted by rowan194

How does something like this work, then? Seems to have all the right sections, but it's missing the resonator and rear muffler.

http://www.ebay.com.au/itm/2-5-CAT-B...ts_Accessories

Wondering what I should do in the meantime, tie up the muffler with some wire (but risk the pipe breaking completely), or just leverage the whole thing off? Or not drive the car at all?

I wouldn't be planning any long drives if I were you. and if you have too, keep the window down , the amount of fumes that can get sucked into the cabin with it broken off there is not good.

EvilChief · 20-04-2013, 10:45 AM

Quote:

Originally Posted by xrghiawagon

All cars should have a muffler and/or resonator on the rear to be legal.

Say what?

You need to meet noise regulations and emission regulations, how you achieve this is not stipulated. If it is by the means of a turbo cat and center muffler, then you are just as legal as having a rear muffler/resonator.

XRGhia · 20-04-2013, 02:53 PM

Well tell that to the EPA, had a few warnings for no rear muffler/ resonator...

EvilChief · 20-04-2013, 07:50 PM

must be a NSW thing then ...

most aftermarket "sports" system cut the rear muffler out and are ADR approved.

4ford · 20-04-2013, 11:03 PM

There are two joints in the factory 6-pot system, shortly after acquiring my AUII Fairmont, I had the local specialists cut off the rear muffler and replace it with a 'hot dog' (straight through) muffler.
It was relatively cheap and the car now sounds good (not at all loud) and the hot dog will last forever (well, almost!).
Had that fitted 10 years ago in September, and its still sounding/looking good!

Crazy Dazz · 22-04-2013, 03:57 AM

Quote:

Originally Posted by rowan194

How does something like this work, then? Seems to have all the right sections, but it's missing the resonator and rear muffler.

http://www.ebay.com.au/itm/2-5-CAT-B...ts_Accessories

Wondering what I should do in the meantime, tie up the muffler with some wire (but risk the pipe breaking completely), or just leverage the whole thing off? Or not drive the car at all?

We've had 4 AU's, only the Fairmont had one. It will be noisier without if you like that sort of thing.

I would not be driving it in that condition, not only do you risk a lot of nasty stuff coming up into the cabin, but risk getting the car stickered.
If you are waiting on the parts, and must drive, I'd recommend a "muffler bandage" as a temporary measure.

rowan194 · 22-04-2013, 12:20 PM

Quote:

Originally Posted by Crazy Dazz

We've had 4 AU's, only the Fairmont had one. It will be noisier without if you like that sort of thing.

Interesting, I always figured only the Fairlane/LTD had a quieter exhaust. I don't mind if it's a bit louder, but I'm not really after the "hey! LOOK AT ME" kind of sound.

Quote:

Originally Posted by Crazy Dazz

If you are waiting on the parts, and must drive, I'd recommend a "muffler bandage" as a temporary measure.

Cheers for the suggestion - will head down to supercheap today. I don't expect the repair will last for long, but it doesn't need to. I've decided to get some quotes from local exhaust places for supply & fitting, since freight to my door is going to cost almost as much as fitting it locally. If it wasn't my daily car I'd have a go myself.

So is a 2.5" redback or supercat a reasonable system (bearing in mind it is budget)

rowan194 · 22-04-2013, 03:40 PM

Some more pics...

Here's the little wire loop I did to help support the muffler (the cracked area seems to be holding most of the weight)

This is worse than I expected. You can see daylight!

Sanding the pipe preparing to apply the patch, I realise it's more than a crack, the whole top has caved in. Can only see this part by taking a photo with my phone.

The connection to the front muffler isn't looking so great either.

So I'm replacing everything past the cat, but the thing I'm wondering, is the cat likely to be rusted out too?

**Whoosha** · 22-04-2013, 08:19 PM

Gees Man do ya self a favour and piff the whole thing before the fumes KILL you. If your light on cash just go to the wreckers

**redxm** · 22-04-2013, 10:10 PM

where ya at mate?

rowan194 · 23-04-2013, 09:54 AM

Quote:

Originally Posted by Whoosha

Gees Man do ya self a favour and piff the whole thing before the fumes KILL you. If your light on cash just go to the wreckers

Yeah definitely, getting it fixed today hopefully, if they can fit me in. Front muffler, resonator, rear muffler. I hadn't realised the corrosion was so bad, I'm actually a little freaked out thinking that the hole has probably been there for some time... I've been limiting driving to the absolute minimum and keeping my windows open since I discovered the muffler sag last week, but what about before then?