Engine/Transmission (1998.5 - 2002) Removal of stock muffler...

[JyRO]

I'm looking at buying the straight pipe from Geno's. I'd like to remove my stock muffer (leaving the resonator) and use the stock hangers.



If I do manage to back off the nuts from the hangers (looks like it'll take a 15mm deep well socket), can I twist, push, pull, tug, & yank on that stock muffler and manage to get it off the existing pipes without a cutting torch?



My idea would be to slip the straight pipe into the muffler position and use the same hangers with no cutting of the stock muffler or welding of the new straight pipe.



Is any of this possible? TIA.



- JyRO

 

[Turbo Terry]

I used a saw-zal and made up some new hangers from NAPA. If thats any help?

 

[Diesel Gunner]

Man, I don't know why you want to work so hard. Take it to a muffler shop and in about 20 mins. they can get the muffler off with the hot wrench and have a piece of four inch in its place.



I found a shop that did it for $60 and everything is welded in place and solid as a rock. I just had to throw my . 02 in.



If you want to be able to put the stock muffler back on and make it look like it was never removed, OK. I kind of doubt that you will be very successfull, though. That stuff is crimped pretty seriously and all I have ever heard anyone say is that the end up beating the snot out of the muffler getting it off.



You will like the way it sounds when you do get it off, though. It also will lower you egt a little bit and fuel economy might gain a very small amout. I run mine with no silencer ring.

, a BHAF and an exhaust brake and like the sound of it. Its not the meanest one on the street, but its mine.



Good luck, and have fun.

 

[Adam]

Split it like a banana

I just did the Geno's MEK conversion, and while I like the sound, I'm thinking maybe I should have just put the money toward a turbo-back 4" system . The clamps that hold the muffler over the resonator and tailpipe where clamped so hard on mine that they crimped both pieces. I ended up taking a cut-off wheel and opening the muffler up like a banana then getting in there with an air chisel and prying it open. If you're careful, all the old hangers will work, except the one on the muffler, but you really don't need it anyway. The only thing you're supporting is a piece of 3" pipe about 2. 5' long. It's way lighter than the muffler. The big thing is to not expect the front clamp to just come off. It's welded to the muffler on both sides near the bottom, so be prepared to do some chiseling or cutting. Also be aware there are locating tabs on the tailpipe and resonator to prevent the muffler from rotating. I zapped these with the air chisel too, made it easier to fit the MEK in place, and gave me more pipe overlap. FWIW, I didn't notice an increase in noise while it's idling during warm-up, and if my neighbors have, the ain't mention it yet !

-Adam

 

[jerryrigg]

I have to agree with Diesel Gunner... except it only cost me $40 to straight pipe it from the downpipe back

 

[Okie-Go]

I think the best my truck ever sounded was with the factory pipe and the me kit from geno's. I left the resonator and it sounded real good. I am thinking of making it 4" straight all the way but thought it may be a bit too loud. The muffler shop guy said if I didn't like it we could weld the muffler back on. How much noise does the resonator stop if any? I can buy a piece of 4" for about 20. 00

 

[Scrappy]

muffler elim

I totally straight piped mine, It is a little louder than with just the muffler removed. the only drawback is the drone I have around 1800 rpms, the stacks also make this more noticeable.

 

[Okie-Go]

That is the reason I have left the muffler on. I have no drone and I like the performance just it sure is quiet. At 75mph I have no drone. I am afraid to mess with something that is working so well.

 

[Fireman Dave]

Jyro,



A few of us in WI did it like you're asking. We used a torch to heat it up and it slid off pretty easily. We all have it a little different now, but mine is straight 4" from the stock resonator. Our theory is the resonator may help avoid the dreaded drone. The straight 4" piece goes to a 4" Walker tailpipe (has all the right bends). New hangers were fabricated with some steel rod, welded on, then put through the stock rubber mounts. The new hangers are threaded on the ends with nuts to keep them from popping out. The total cost for my truck was about $100. for the tailpipe, 4" piece (that we cut up and shared), and a cool 5" chrome tip (made for a motorhome). Thanks to johnrv4 for the welding help and hanger fabrication.



My stock muffler with the tailpipe still attached hangs in my garage rafters. It could be bolted right back on any time if I wanted to. But I don't. It sounds great! I'm happy with mine.

 

[JyRO]

I guess I just don't do anything...

the easy way. For one thing, I realize there's easier ways to do this. But my idea is that I can unbolt this straight pipe, throw the muffler back on it, if I were to move to an area that had inspections. Or if I didn't like the added noise (ahem, sweet sound) any longer (fat chance).



Also, I want to keep my truck looking as "stock" as possible. I know its not going to sound stock any more, but I heard one a couple weeks ago that I think just had the m. e. k. and it sounded great. I'll leave the stock pipe from the muffler back to retain the stock look.



I like fireman's way the best so far. Looks like its going to take some heat to get that thing off. I checked it out real good the other day and it does look as if the C clamps around the pipes are welded or rusted together. It looks tough. I may well wind up beating the snot out of it . But that's the way it goes I guess.



- JyRO

 

[rashwor]

Muffler fell of last Friday...

I drove by a muffler shop last Friday and my Muffler just fell off on his shop floor. The resonator is still intacted and there is no drone at any RPM.



Sounds sweet and the Mrs. road in it all weekend and never noticed! Oo.



I love the sound and will never go back! No affect on mileage or power, but then I did not expect any either. Foot is too fat for that!

 

[Fireman Dave]

Jyro,



You will most certainly need heat to get that thing off intact (mine needed it with only 22,000 miles on it), but it's worth it to do it that way, IMO. Then you could just bolt it back on down the road if you want to. Maybe having a shop help out for a reasonable fee would work. Or, put a shout out to MI TDR members. Someone surely has a torch. TDR guys just love to help each other out, and this is a simple and quick job. If you can, take it off without wrecking it - you'll be glad later.

 

[mgoncalves]

I did mine like fireman's, I love it, I think fireman was the one that gave me the part # for the tailpipe. It takes all the work out of it.

 

[Lsfarm]

No Heat needed

I used a bottle jack between the muffler and the resonator and pushed the muffler off, No heat needed, just three hands.



Greg L

 

[Okie-Go]

4" resonator

Who or where was it that a 4" resonator could be had. If I do this I want to have stuff lined up and not get caught with my shoes off so to speak. I would think a resonator might be nice to avoid the drone especially on an all day trip pulling the 5er at freeway speeds.

 

[Casey Ray]

Went out for lunch today and passed a muffler shop, pulled in to ask how much to remove the stock muffler and the darn thing just fell off right there in his shop . He charged me $30 to weld in a straight pipe. He also welded on custom hangers. I notice a very little increase of noise in the cab, but haven't driven but about a mile with the change, had to go back to work also had the windows down. So far so good, I like it.



Bocifus