[T3] Muffler Nuts...cont'd...

Jim Adney jadney at VWType3.org
Thu Oct 6 17:15:24 PDT 2016

Those threads are always hard to get started straight. This is partly 
because the the end of the tube coming out of the HE isn't usually 
square with the axis of the threads. Keep trying; you'll know when 
you've got it right, because it won't bind up as it goes in. You'll 
never get it to seal unless it's in there straight.

Don't forget that there needs to be a crushable metal gasket in 
there, too. Without that, you'll never get it to seal, and you'll 
need to clean out the remnants of the old one first.

A good sign that you've got the threads straight is that the HE is 
now hard to turn on the muffler. Yes, you want to leave it a bit 
loose until you get the whole assembly mounted on the engine, but you 
want to confirm that it's assembled correctly before you get that 


On 6 Oct 2016 at 22:25, J. Jonik wrote:

> Muffler Nuts and Heat Exchangers continued...
> Problem:  Big nuts holding Rear Heat Exchangers to Muffler were seriously frozen.
> So...garage down the street said, ok, cut the muffler off at the heat exchanger pipe and bring 'em in.  Did that.They then used Real Heat and power tools and the rest and got the nuts off the exchangers...at $15 a pop.   They said the job was difficult...but not in those exact words.
> Back home (up the street) I managed to get the left exchanger threads started onto the new muffler and tightened down to where I'll tighten the rest of the way when it's in the car.  The right (smaller) exchanger didn't have such cooperative threads...and was more awkward to play with and hold and get good access...but after hours...and no access to an inside re-threading tool, I got it started...to maybe 2/3 of the way on...not as far as the other one.     With some metal damage from the "heat wrench" treatment, it's not visibly clear if the threads, at this point, are exactly lined up where they're supposed to be.   It MAY be going on straight, but, with the heat-battered metal, it's hard to tell for sure.
>    But, what if the threads are off a touch, even with heavy tightening when it's bolted to the engine?   Will that provide enough sealing to keep exhaust from leaking?   Is that the only concern?
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Jim Adney, jadney at vwtype3.org
Madison, Wisconsin, USA

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