Help! Can't get exhaust pipe out of end of muffler

[Amos1]

I'm trying to replace the rusted-out exhaust and tail pipe on my Ford 801.

I Can Not get the exhaust pipe to slide out of the muffler...

I cut the pipe off about 5 or 6 inches from the muffler so I would have enough clearance to rotate and pull on the pipe, hoping it would slide out. I AM Able to rotate the pipe around freely and wiggle it up and down somewhat, but I still can't get it to slide out of the muffler :thumbdown:

I'm about ready to unbolt the muffler exhaust flange from the exhaust manifold so I can take the muffler and stuck exhaust pipe into the garage to try and remove the pipe.

If push comes to shove, I'll buy a new muffler so I can insert the new exhaust pipe in it. BUT - I'm kinda worrying if I'll have problems getting the muffler of of the exhaust flange, too. (I've read you Do Not want to get too rough with the manifold as it might crack. That would make my head hurt even more, not mention my wallet)

Anyone else ever had this problem - exhaust stuck in muffler? If so, how did you solve the issue?

Thanks for any suggestions !!!

 

[kevin37b]

Take a grinder and cut off wheel and carefully make a few relief cuts vertically in muffler .

 

[Amos1]

Take a grinder and cut off wheel and carefully make a few relief cuts vertically in muffler .

By vertically, you mean a cut from the big part to towards the snout, correct? (There are 1 or 2 I can see that were already made on the muffler, but I'll try cutting 1 at a time and see it that works.)

Great idea! Thanks, Kevin

 

[skyhook]

WD40 and heat ( torches) the muffler if yo can, the muffler will expand so you can pull the tail pipe out.

 

[kevin37b]

Yep and a small chisel might help . Good luck .

 

[treefarmerguy]

With a sawsall or hacksaw blade make a cut from the end of the exhaust pipe to the end inside the muffler with out cutting into the stub from the muffler. then take pliers and twist the pipe as if trying to roll it up long way. It should slide right out.

 

[bigtiller]

If it is in this tight, it may be just as difficult to get the new one in without a pipe expansion tool. How much does a muffler cost? That tool could be pricey.

 

[JRobyn]

Got access to an air chisel?
8" MUFFLER & TAILPIPE REMOVER MC387A | Matco Tools

 

[flyerdan]

I'm thinking that if the pipe will rotate, it is probably trapped in a groove caused by a muffler clamp. Probably have to whip up some kind of puller to extract it and then take the groove out of the muffler with a HF pipe expander so the new pipe will go all the way in.