Replacing muffler

[Ziggyfernz]

Hello All,

This is my first post into this forum! Great to meet everyone...

Now i have a problem i need to replace my rear muffler on my 1997 ford explorer XL. The muffler as you know has a 2 in 1 out. Now i am looking to do this fix as cheap as possible. The issue i have is by the looks of things if i buy a muffler myself it has a weld on the single outlet pipe to the rest of the tail pipe. When you purchase a muffler it only is the muffler with no tail pipe?

Is there a way to replace the muffler without a weld?

Thanks for the help in advance!

 

[RickOTR]

Rockauto has a variety of direct fit mufflers that don't require welding. If you go aftermarket then you will need to weld the exhaust to the muffler. To get a good muffler that will last you for a while is about $50-$90.

 

[Ziggyfernz]

Thanks for the reply ill check. The rear hangers on the tail pipe are completly rusted off. Do you think it will be easy to weld the hanger back on?
Plus rockauto is in the states

 

[jremington59]

The rear hangers just bolt to the frame. The 4.0 and 5.0 for that year both take the same exhaust from most places.

 

[Ziggyfernz]

Well the hangers are rusted off the rear tailpipe. So not sure what YOU are getting at with that comment?

 

[drdoom]

Ziggy, it is common for those "horns" to rust off the pipes/muffler. You should check out Walker direct fit and you can get the resonator/tailpipe too. They all just clamp & bolt back in, and the hangers are all on there. As I recall you need to cut the one old inlet off, and be careful with that you need to do it in the right place. And just get new bolts for the flare side inlet. Also I found it helpful to make a cut in the old tailpipe to make removal of the old exhaust easier. No welding required.

 

[jremington59]

Well the hangers are rusted off the rear tailpipe. So not sure what YOU are getting at with that comment?

What I'm getting at is the tailpipe comes with the new hanger installed and it slips into the rubber hanger in the rear frame. There's one for the tail pipe and two on the back of the muffler. If you slap some grease on them they slide right out. I just replaced mine last week and it took a couple hours. Most of the time was spent cutting the old bolts off the flange. I wish my 2000 had the same setup. It doesn't get much easier. Here's a nice kit for the price.

http://www.summitracing.com/parts/wlk-17352/overview/year/1996/make/ford/model/explorer

 

[Ziggyfernz]

Thanks for the information guys! I think ill look into getting a catback system that will atleast cover all my issues. New bolts on rear tailpipe and replacing the muffler.

 

[jremington59]

If you check here you can probably put a system together for a little cheaper buying the muffler and pipe separately if you don't want a cat back. They have a direct fit muffler for 65.00.


http://www.rockauto.com/

 

[Ziggyfernz]

Hello,

What do you think about this system? It will fit my car by the looks of things.

Seems good? Anyone have tried this brand?

http://www.ebay.com/itm/97-to-11089...ntaineer-Muffler-exhaust-system-/200922500569

 

[99explorersport4.0]

 

[Terkins]

Rockauto has a variety of direct fit mufflers that don't require welding. If you go aftermarket then you will need to weld the exhaust to the muffler.

I noted my tailpipe hanger is about to rust off (only 25% remaining). The system looks to be welded (is the original possible after 20 yrs.?) I'm investigating 'possibilities' before it (tailpipe hangar) breaks this winter, not wanting to open a 'whole can of worms' (ie. "If it isn't broke: Don't 'fix it'!")
The Rockauto tailpipe says: "OHV Only; Side exit replaces rear exit O.E. Design; If welded assembly, replace all required parts." (How do I know?)

If this is the original (20-yr.-old) system, then it seems logical to (at least) go for the Int. Pipe (41831)+Muffler (21192) + Tail Pipe (55030)?
Is this being "too cheap" on the fix? (ie.: NOT re-doing the Front Pipe/Converter seems avoidable, for now?)

 

[Terkins]

I noted my tailpipe hanger is about to rust off (only 25% remaining). The system looks to be welded (is the original possible after 20 yrs.?) I'm investigating 'possibilities' before it (tailpipe hangar) breaks this winter, not wanting to open a 'whole can of worms' (ie. "If it isn't broke: Don't 'fix it'!")
The Rockauto tailpipe says: "OHV Only; Side exit replaces rear exit O.E. Design; If welded assembly, replace all required parts." (How do I know?)

I spoke too-soon. I see now the Walker Kit 1500218/ $150.99 has the goods in it.

 

[J_C]

View attachment 174722 View attachment 174723
I noted my tailpipe hanger is about to rust off (only 25% remaining). The system looks to be welded (is the original possible after 20 yrs.?) I'm investigating 'possibilities' before it (tailpipe hangar) breaks this winter, not wanting to open a 'whole can of worms' (ie. "If it isn't broke: Don't 'fix it'!")
The Rockauto tailpipe says: "OHV Only; Side exit replaces rear exit O.E. Design; If welded assembly, replace all required parts." (How do I know?)

If this is the original (20-yr.-old) system, then it seems logical to (at least) go for the Int. Pipe (41831)+Muffler (21192) + Tail Pipe (55030)?
Is this being "too cheap" on the fix? (ie.: NOT re-doing the Front Pipe/Converter seems avoidable, for now?)

Sure, if the CAT is still good you can buy separate pieces or that kit you mentioned which just bolts to the flange on the CAT. I don't know for certain about that particular Walker muffler part #, but the Walker for my 4.0L SOHC '98, has the inlet and outlet tubes sized to slip fit with their tailpipe part #, and probably in your case, also the "Int pipe" piece so it just slips together then uses the U-bolts suggested, or you could get lap joint clamps instead of U-bolts if you feel like paying more money for them, to make it easier to get apart later, because a lap joint clamp doesn't crush the pipes together in one spot to create an impediment to slipping them back apart once the clamp is taken off (and rust has set in).

Note that the $150 price for the kit on rock auto is a little higher priced than separate parts. On Amazon that muffler is $59, the tailpipe is $35, the int pipe is $13 to $22 depending on 2-dr vs 4-dr. That's $116 delivered (free amazon shipping), leaving around (guesstimating) $50 on the table (vs Rock Auto kit price of $150 + shipping) to get two clamps, two gaskets, and the bolt kit, for example those on Rock Auto should be a little under $35 delivered, remembering to use the 5% off RA coupon code, maybe less on Amazon if they have all the parts so you avoid a Rock Auto shipping charge, -OR- instead of the two u-bolts you could get a couple of lap joint clamps on Amazon for around $20, again assuming the muffler has the slip-joint tubes like mine (different Walker part # muffler) does so you'd want lap joint clamps instead of butt-joint.

... or just buy the kit, I just find it odd how their kits end up costing a little MORE than buying the pieces separately when they should give us a little price break for buying the whole kits.

 

[Terkins]

Sure, if the CAT is still good you can buy separate pieces...Note that the $150 price for the kit on rock auto is a little higher priced than separate parts. On Amazon that muffler is $59...

[FYI: $234.14 total for the same parts at Autozone as in the RockAuto kit (coupons for $20./off vs. 'free shipping' (hint: nothing is 'free').]
Also, there are two different mufflers that Walker makes: cheaper/1yr. warranty (#18573) and other/lt. warranty (#21192; $58.84 Amzn/ $87.79 RA; $102.99 PartsGeek).
Amazon 'free shipping' helps to stamp out local small businesses/competition. I'd rather pay FedEx to deliver/support RockAuto (vs. Amazon).
"Thanks J_C" for your comments.