The 940 failed state inspection (again) yesterday because the front muffler is rusted and the mechanic said it should be replaced. I went to FCP and saw that I can get the front muffler, hanger and bracket for about $90. The rear muffler was replaced not too long ago, so I'd rather not waste what little cash I have. If i just get the front muffler, would it be overly difficult to install myself? I don't have a lift unfortunately, and I'm sure there will be plenty of rusted hardware. Will any welding be required here? Or would a decent assortment of sockets handle the job?

 

cut it out and couple a piece of pipe in with clamps on each side, no welding. I am in NC and it was fine for me.

 

I would include a good jack and jack stands as necessary tools. Never get under a car unless it's on jack stands and you've checked that it won't fall off. You may need new clamps to hold the pipes together and maybe some penetrating oil to break down some rust. It's not a very difficult job, but rust connection can be frustrating. I like PB Blaster to break down rust. I took my exhaust manifold off and every nut came loose easily after a shot of PB Blaster to them. It had several hours to soak, but since I knew I would be doing the job later, I shot it on the night before. That may help, and it may not be necessary.

 

What about replacing that muffler with a straight pipe? I figure it would save me some cash, and I assume it would still be legal since there still is a muffler on the car. I'd like to do the job this weekend and that definitely seems easier.

edit: I think this its what bigdaddy was talking about, but I was looking for more clarification...does it make the car louder? I know the law here (maine) is 95db, which is kind of loud. I think as long as the thing doesnt leak/be rusty I should be ok. To be honest, I kinda like the noise, but the powers that be do not.

 

Im from Maine, and i only have a rear muffler, no front or cat. Its fine noise wise, and no emissions. As far as replacing the front Muffler, eeuroparts.com has them for a bit cheaper i think. Very easy to replace. Just a few jack stands works wonders. I finished my exhaust up today.

 

unfortunately the inspection was up in january and I'd like to get it done this weekend. I'm thinking of going with motor supply for the pipe. Advance auto only has 18" pipe which i think might be too short...
Schwalbel, did you remove the front muffler or was the car like that already?

 

tools that might be helpful
hacksaw
sawzall
stupid hot torch (its amazing how pliable steel gets when heated slightly)
flat head screwdriver
pb blaster