Can you cut off a muffler just past the flex pipe?
5.0 V8 in a '92 E 150 single exhaust

(copied from exhaust forum)

A few weeks ago I was driving this old van around the neighborhood to try to check out an engine problem (since fixed) when I suddenly heard the most ghastly noise coming from beneath the van. The muffler flange on the downstream end had rusted off and the tailpipe was dragging on the pavement. I got it home and took off the tailpipe and removed the clamp from the end of the muffler.

I went to Autozone and ordered a replacement muffler (Walker) with the intention of removing the front clamp and installing the new muffler. But when I got back under the van to do that, I discovered that the muffler was welded to the flex pipe. The weld seems to be spotty and is mostly at the upstream end on the flex pipe.

I think I could take a Sawzall and cut the front flange of the muffler near the muffler body and use a cold chisel or some other tool and remove the rest of the flange and install the new muffler using clamps.

Is this a no-no? I don't want to damage the flex pipe. And I sure don't want to take this old van to a muffler shop if I can help it.

Any help greatly appreciated.

 

just did a quick look at Rock Auto listings for your year exhaust and they sell a flex pipe piece that clamps onto the back of the cat converter and on the muffler on the other end.

If you have a solid piece of pipe on the back of the flex pipe to clamp the muffler onto, you might be OK, but clamping onto flex pipe ain't gonna work. Aftermarket exhausts frequently break the system down into smaller pieces than factory (OEM muffler was likely a unit with the flex pipe); they certainly ship easier.

Good luck,
George