1991-1993 240sx: Rear stock muffler replacement tutorial

[vancouverbc]

Introduction

This is a very easy procedure. If any of the bolts give you trouble, just keeping twisting and they will break. The cost is about $160 US for the piece going from cat to tail pipe. It only weighs 25 lbs. Rock auto had the best price.(bosal muffler fitment was off. the hangers welded to muffler were in wrong place. have to change that)



Tools

LOCKING WASHERS IMPORTANT

-jack will help lift muffler to get insulators back on

-New gasket-New bracket for ground?

-Only use steel bolts . Make sure you have locking washers. The old ones will have no spring left.

Procedure

1.Remove the two 13 mm nuts holding on the insulator closest to muffler. You can grease these insulators a bit to help them slide. I used a screwdriver to slide the insulator off. .( insulator, washer, 13 mm nut, locking washer, 13 mm nut). The welded bolt comes welded to muffler.You may have to remove the bolt holding this insulator to floor of car to get new muffler on. Dont break this bolt.



2. Remove the 12 mm head bolt that holds insulator to resonator.(bolt head, locking washer, washer, insulator)(Replaced with m8 by 40 mm with 13 mm head)



3. Remove the grounding wire that is close to cat. It is held on by muffler bracket. I unscrewed the 10mm head bolt that attached wire to floor of car.



4. Unfasten the two 14 mm bolts at the cat. Let the muffler drop to ground.(see cat tutorial for details on bolts/washer etc needed)



5. Unhook the insulators that attach muffler to car. No bolts.



Modified by vancouverbc at 2:29 AM 4/24/2009

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Modified by vancouverbc at 2:10 AM 6/4/2009