I replaced my entire exhaust system from Cat back, because of holes in the muffler and a great price on the Saab/Remus performance exhaust. Replacing just the muffler would be very similar, since the Saab/Remus kit comes in two pieces.

I strongly suggest removing the entire system from the Cat back so you can do the measuring and fit-up in an open area. The splice joint for a new muffler is in a congested area beneath the car, OK for a wrench but not a saw. My old mid-pipe was nearly pristine when I inspected it after removal, so a muffler only replacement is a valid money saver.

Tools: Ramps, floor jack, variety of wrenches, penetrating solvent, saw, screwdriver or putty-knife.

Procedure:
1) Drive car onto ramps
2) Soak the two bolts securing the mid-pipe to flange behind the Cat
3) Place floor jack under muffler and just snug it
4) Start removing the rubber muffler hangers. The retaining clips slide off sideways, use screwdriver or putty-knife to pry clip slightly to open. The 90-degree finger is NOT the pry point, that is the rear of the clip, It slides off the other way - see groove in front.
5) Unscrew the nuts on two bots you previusly soaked with solvent
6) Lower floor jack and pull system out the rear of car
7) Lay-out the new muffler adjacent to old system. Mark the correct spot to cut old pipe, remembering to leave pipe for insertion into muffler socket.
8) Assemble system, placing new muffler on floor jack after sliding system under car.
9) Reverse steps 5 thru 1.

Total job took me less than 90 minutes, maybe less than 60. My car had 90,000+ miles and was nearly 4 years old at time of replacement. Nuts still screwed off easily after soaking with penetrant.


2000 lpt Sedan
104,500 miles

posted by 198.208.15...

• Muffler Replacement Question, Sean, Mon, 8 Mar 2004 18:23:05
  • Re: Muffler Replacement Question, Kirk Daehnke, Tue, 9 Mar 2004 13:27:48
  • Re: Muffler Replacement Question, compaqted, Tue, 9 Mar 2004 05:53:22
  • Piece of cake...., Roger, Tue, 9 Mar 2004 03:41:08 <-- Viewing This Message
  • Re: Muffler Replacement Question, Steve Crowe, Mon, 8 Mar 2004 21:09:40
  • Really Easy, Stephen Goldberger, Mon, 8 Mar 2004 19:41:00
  • I don't know about saab mufflers but, Dennis, Mon, 8 Mar 2004 19:34:52

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