Chevrolet Full Size Cars 1979-1989

Muffler

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Safety glasses should be worn at all times when working on or near the exhaust system. Older exhaust systems will almost always be covered with loose rust particles which will shower you when disturbed. These particles are more than a nuisance and could injure your eye.

REMOVAL & INSTALLATION



  1. Raise and support the front of the vehicle safely using jackstands.
  2.  
  3. Spray all fasteners which are to be disconnected using a penetrating oil.
  4.  
  5. On the single pipe system, cut the exhaust pipe (wearing safety glasses) near the front of the muffler. ON the dual pipe system, remove the U-bolt clamp at the front of the muffler and disengage the muffler from the exhaust pipe.
  6.  

Before cutting the exhaust pipe, measure the service muffler exhaust pipe extension and make certain to allow 1 1 / 2 in. for the exhaust pipe-to-muffler extension engagement.

  1. At the rear of the muffler, remove the U-bolt clamp and disengage the muffler from the tailpipe.
  2.  
  3. Remove the tailpipe clamps and the tailpipe.
  4.  
  5. Inspect the muffler and the tailpipe hangers; replace if necessary.
  6.  

To install:

  1. Add sealer to the connecting surfaces.
  2.  
  3. Loosely install the front of the muffler to the exhaust pipe and to the tailpipe.
  4.  
  5. Check alignment, then tighten the fasteners starting at the front of the muffler.
  6.  
  7. Remove the jackstands and carefully lower the vehicle.
  8.  
  9. Run the engine and check for leaks, but be careful NOT to touch the hot exhaust pipes. Be especially careful near the catalytic converter.
  10.  

 
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