[T3] Muffler Nuts...

Dave Hall dave at hallvw.clara.co.uk
Tue Oct 4 15:09:19 PDT 2016


In the early days of ownership, I managed to undo those large nuts. The
manual calls for graphite paste to be used to assemble - I bet most places
(and owners) rarely use it when renewing a muffler.  Over the years I've
often obtained and fitted part-used mufflers which invariably come with the
upper heat exchangers well stuck on. The only suggestion I can make is to
make up a block with two holes to bolt the flange to, hold that in a big
vice, heat the nut to cherry red and use a Type 2 46mm socket with 3/4"
drive and extension bar if needed, or better still, a powerful air impact
driver. If it releases, check the fine threads are still useable!

If you don't have enough muffler left to save, there's no point in keeping
the scrap body in the way of the job.

I expect the VW way was to replace the upper heat exchangers too.  At the
labor rates the dealers charge, they probably would only have cost a couple
of hours time each!

Dave
UK VW Type 3&4 Club
===================

-----Original Message-----
From: type3-vwtype3.org [mailto:type3-vwtype3.org-bounces at lists.vwtype3.org]
On Behalf Of J. Jonik
Sent: 04 October 2016 22:56
To: type3 at vwtype3.org
Subject: [T3] Muffler Nuts...

Re/ '72 T-3 Standard....Muffler.
Muffler has bad rust holes, helped by one backfire (caused by
absent-mindedly mis-plugged wire to coil).    Car sounds like Hell's Angels
going up Hwy 101.   No muffler patch job this time.
Trouble is, unlike other times in the past doing muffler removal/replacement
job, this time the two nuts holding the muffler to the Heat Exchange ducts
Will Not Budge. 
 Got the right size flat wrench for the job...used 3 ft breaker bar...tried
chiseling with heavy hand sledge...tried propane heat...tried hammering the
wrench...nothing moved.  CRC or Liquid Wrench are no good because fluid
won't go up-hill.
   Gave up and took car to nearby shop.  They tried a Six Foot breaker bar,
with two big guys on the handle.  The car turned, but the nuts didn't.   
Not sure what else they tried the second time, but they didn't want to use
Serious Flame because of all the oil nearby.
   Plan now is to take muffler and heat exchangers off together....Soak the
nuts on upside down assembly overnight with CRC or Liquid Wrench...and try
getting the nuts off again...or having the garage guys give it another
whack.
  Is it unimaginable that the nuts Will Never Come Loose?...that time,
corrosion and heat welded the metal together forever?   Are there some
secret VW tricks to do this job?   At least, with heat exchangers no longer
bolted to engine, they won't get bent out of shape doing this job.

 Problem is that replacement Heat Exchangers may not be available for
thousands of miles...and then will probably cost a fortune.  It was pure
luck that got me the "new" unused muffler.
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