REMOVAL & INSTALLATION
To remove the muffler from all Volkswagen models, first remove the clamps from the muffler and heat exchangers. (Early 1963 and earlier models do not have exchangers.) Remove the clips connecting the warm air channels. Loosen the clamps on the tail pipe(s) and remove the tail pipe(s). Remove the nuts from the muffler flange and remove the pre-heater adaptor pipe. Remove the four screws from the manifold preheater pipe and take the muffler off, including gaskets. Check the muffler to be installed and the exhaust pipes for leaks or damage. If necessary, the exhaust pipes can be re-used. However, in practice it is often difficult to remove the tail pipes from the old muffler without damaging them extensively. This generally occurs with old mufflers that have become rusty, and in such cases it is advisable to install new tail pipes. Type 1 tail pipes should protrude about 7.5 in. on pre-1968 models; 8.3 in. on later models. New gaskets should be used when installing the muffler.