Chevrolet Full-size Cars 1968-1978 Repair Guide

Special Tools


A number of special exhaust system tools can be rented from auto supply houses or local stores that rent special equipment. A common one is a tail pipe expander, designed to enable you to join pipes of identical diameter.

It may also be quite helpful to use solvents designed to loosen rusted bolts or flanges. Soaking rusted parts the night before you do the job can speed the work of freeing rusted parts considerably. Remember that these solvents are often flammable. Apply only to parts after they are cool!

Whenever working on the exhaust system please observe the following:

  1. Check the complete exhaust system for open seams, holes loose connections, or other deterioration which could permit exhaust fumes to seep into the passenger compartment.
  3. The exhaust system is supported by free-hanging rubber mountings which permit some movement of the exhaust system, but do not permit transfer of noise and vibration into the passenger compartment.
  5. Before removing any component of the exhaust system, ALWAYS squirt a liquid rust dissolving agent onto the fasteners for ease of removal.
  7. Annoying rattles and noise vibrations in the exhaust system are usually caused by misalignment of the parts. When aligning the system, leave all bolts and nuts loose until all parts are properly aligned, then tighten, working from front to rear.
  9. When replacing a muffler and/or resonator, the tailpipe(s) should also be replaced.
  11. When installing exhaust system parts, make sure there is enough clearance between the hot exhaust parts and pipes, and hoses that would be adversely affected by excessive heat. Also make sure there is adequate clearance from the floor pan to avoid possible overheating of the floor.
  13. Exhaust pipe sealers should be used at all slip joint connections except at the catalytic convertor. Do not use any sealers at the convertor as the sealer will not withstand convertor temperatures.