Neil58

I'm about ready to remove stock muffler and install replacement pipe on my 4.5 3500. The muffler looks like it's crimped on there quite well. Anyone with experience doing this? I would appreciate some lessons learned and helpful hints on how to remove and preserve the stock muffler. I do not want to use the sawzall on it.

Thanks for your input.

Ray Roton

You will most likely have to saw it off. At first, I didn't want to, but then I decided, why not, I'm never going to put that POS back on anyway.

Hoss

An air chisel might do the trick.

IA_James

Exhaust shop that did mine used an air chisel, like you say, they are on there pretty good.

War Nerve

Peel it open like a can opener with an air chisel.

ChuCk

lawnpro

I was searching for a muffler at auto zone and a loaner tool pops up that says " USED TO REMOVE CRIMPS CAUSED BY U-BOLT CLAMPS" and another one is a "tail pipe cutter" http://www.autozone.com/servlet/UiBr...EXHAUST+SYSTEM

surlynkid

miller cutmate 375.

plasma baby.........

OOPS

It's not your wheeler surlynkid!!!!!!

Neil58

I have no problem cutting or chiseling the muffler off.....I will never use it again anyway. I just want to make sure the replacement pipe that Geno's has is long enough if I cut the muffler off right at the inlet and outlet, just at the junction where the exhaust pipe enters and exits......Best I can tell, I will need at least a 42" pipe. Has anyone used the replacement pipe listed on Geno's or are there other places on line that offers it? If so, what is the length?

War Nerve

The Geno's pipe is designed to replace the stock muffler. Make sure you cut the muffler only and NOT the inlet or outlet pipes. Once that's done the "straight" pipe clamps right in. It took me about 45 minutes from start to finish on my back outside in the rain. I used an air ratchet w/ sockets and an air chisel. It's awesome!

cHUcK

wvcowhauler

how does that sound with the cat still on it, and also does it void the warrenty or anything like that???

Neil58

I'm not quite sure how it's going to sound. My plan is to replace the restrictive stock muffler.....see how it sounds.....if I don't like it......put an aeroturbine just behind the cat......if I still don't like it......I will sell the truck and get a Hyundai.

Does it void the warranty? I would be willing to bet the dealer would certainly point out the missing muffler if the truck was brought in for warranty repair.......I may just put the aeroturbine on from the start and be done with it.

I had planned on putting a Nelson 51" on it but that got to complicated.....the thing is huge and I could not find anyone that would bend 4" pipe. The muffler shop could have made it work, but I did not like the way it was going to hang down at an angle. So, I took the muffler back and now going with plan B above.

BTW: Just kidding on the Hyundai part.

v8440

The muffler is slipped on over the pipe that feeds it. Remove the clamps at the front and back of the muffler, and beat the **** out of the muffler with the biggest hammer you can find. Of course, you'll need to swing toward the back of the truck. If that doesn't work, get a cutting torch and CAREFULLY cut "strips" into the muffler from the front of its pipe toward the body of the muffler. In other words, you're aiming the cutting torch toward the back of the truck. The tip of the torch will be basically parallel to the pipe so you only cut the muffler and not the pipe it's slipped over. If you're careful with the torch, you can do this and not damage the pipe. Once you have a few grooves cut into the muffler it'll be more willing to open up at the mouth. Then, beat it senseless again. It should then come off.

Patrolman808

I had to get the sawzall out to cut mine off. It was too crimped down to get the muffler to slide off. Almost had a heat stroke pulling and beating on it, so I just cut it.

dodgedude361

i used a cutting wheel on a 4 inch grinder. had that thing off in less than 5 minutes