Join Date: Mar 2002
Location: Crestview, Florida
Okay, here are my experiences--in theory, changing the muffler is simply a bolt-on procedure. However, I don't fix what isn't broken, so by the time I have ever replaced a muffler, my exhaust system has been so corroded that it would be pure hell to try and separate the two pipes--that's where the ol' Sawzall comes in. A muffler shop can cut your old pipe and weld the new muffler to it easily, though. Unless you have a welder at home, you will probably have to use pipe clamps, which are good for aluminized steel because they don't burn the coating off like welding does, but they can be a real pain to get sealed completely if the two pipe sizes being joined do not have a fairly tight fit. I notice that you are close to the south, but I still don't know how much snow you get. The reason I say this is that I have been told that the front pipe takes a long time to rust out unless you have the salt factor. The heat at that point is intense enough to keep the condensation cooked out. Therefore, if your converter is still good, just work from that point back, and you'll have to be the judge on whether or not your pipes warrant replacing with the muffler (remember that exhaust systems wear out from the inside, so it's usually worse than it appears from outside). To make things even more complicated, there are better pipes (you mentioned Flowmaster wanting $100). I know that Walker uses fairly thin pipes compared to muffler shops I have used in the past, but then they are substantially less expensive also. I would find out the gauge of the pipes and then decide if the thicker gauge is worth the extra cost.
Currently an '86 CJ-7 and a '77 CJ-7 Golden Eagle---#4 and 5 following a '01 Sahara, '90 Sahara, and '85 CJ-7....