Installing new sausage muffler, things to know
 

I bought a new Dansk Sport muffler, and I want to replace it myself.
It seems pretty straightforward from the parts involved
but I wonder if there is anything I need to be aware ('82 SC)?

(eg. the heat exchanger notorious studs, flapper heat bot notorious bolts etc)


from the photo the bolts seems so rusty almost melted... should I just try to cut the nut with a nut cracker to should I give it a try with 2 wrenches?

I guess I need to buy new bolts and gasket ;)

https://i.imgur.com/aLG28Lq.png

Oxy/acet torch makes short work of them. A dremel tool makes it a several hour job. A disc cutter works if you can get it in there.

You can give it a try with hand wrenches (soak the hardware for a few days with penetrant) but honestly, a Dremel will work too.

On my old SC I was able to get all the nuts and bolts off by hand and even re-use them but they looked better than that.

A couple of wrenches will snap those bolts. —Dave


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If you buy the replacement dansk muffler straps the bolts are too short. So you need to swap them with some longer bolts. Pretty well documented issue on the forum, happened to a lot of people including me. Not a big deal but could be a show stopper if you don't have a well stocked garage.

I agree with John, Hot Wrench!!

All but one of mine came apart without much effort, and they looked quite similar. Replaced all with stainless, and no issues changing things out for the biennial test.

Good ol' torch gets 'em off too.

Heat baby heat!
Then hammer a couple of sockets on and they will probably snap anyway.

yeah, i guess even if i break them i can hammer out of the hole...

thanks, guys!

BTW, I don't have a torch, but maybe I can buy one for the future, what do you recommend something small just portable for small jobs? can the torch I use for Creme Brulee work : haha

You need alot of heat. A creme brulee torch is too weak. MAPP gets you closer but Oxy is needed on that level of rust.

If you don't have/like an open flame, use an induction heater like a bolt buster. Amazon sells knockoffs that work just as well.

oh good to know.

in my specific case that I don't need to save anything I guess a nut cracker would be enough if the wrench and lubricant won't work.

other than that, I see there are only two metal straps that hangs from a brake and that's it correct?

do I need any compound between the gaskets? or straight metal gasket metal?

Its just the bolts and straps that hold it together. While you may not care about the old muffler, it still bolts onto the existing cat. If you snap those bolts just be prepared to drill out whatever is left on the other end.

Metal gaskets only.

Those are through-bolts between the muffler and the cat. Nothing to drill out if you snap them. Agree on the metal gaskets.


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This is the rare instance where you want the bolts to snap (decisively and quickly). Start there. Then, if you can't get a box end wrench on what's left of the nuts & bolts... HEAT, (although Oxy isn't in the purview of the home "mechanic").

Best Case scenario is that all three bolts snap AND the strap bolts come off (otherwise, use a grinder to cut the straps off).

Then, grab the muffler tip and the right side of the muffler and crank it off as you watch the nut & bolt remnants, gasket and rust dust hit the floor.

May the odds be ever in your favor.

Something else to look out for: If your new muffler has the 3.2 heater crossover pipe cutout in it (the indents in the below pic), it may require a different hanger and straps than the original muffler. You can also expect the passenger/right side to sit higher than the left.
https://i.imgur.com/JX7uoeHl.jpg
https://i.imgur.com/RgF66sFl.jpg

Sawzall with a good metal blade solves all my problems😜

The Sport Danks muffler seems to have the indent yes

but why it sits higher on the right of your car? isnt the same shape/size as the original muffler?

also, why did you remove the entire rear bumper? it seems such an easy job just jacking the rear and maybe removing the rear wheel on the driver's side no?

i actually found a photo of the reason for those indents... but my 82 SC doesn't have the pipes like that... my heat exchangers are distinct left and right

https://cimg4.ibsrv.net/gimg/rennlis...8cd855d387.jpg

TeeJayHoward
can you please tell me which straps did you order? the OEM part 90111115704 clearly is too short. I received today the muffler and new straps and I cant belive they don't fit...

did you order these maybe?
https://www.pelicanparts.com/More_Info/90111115704.htm?pn=901-111-157-04-M124&bc=c&SVSVSI=0574

There's a left strap and right strap.... kind of odd, but clearly shown in the above pic.

One strap is longer to go around the heat exchanger pipe up to the heat fan, the other goes around the mount on the engine.

If you deleted heat you will need shorter straps.

Pelican sells the left and right straps, maybe you bought two of the shorter straps without knowing this.

https://www.pelicanparts.com/search/?q=muffler+strap