Time to replace the muffler. Looks like a PIA on this van (extended). After the resonator the pipe is a single piece, a short piece of flexible tubing, then the muffler, then the tail pipe, all welded together, including the hangars. Is this normal? For those of you who changed out your muffler, how did you do it? And did you re-install a heat shield? Thanks,

John

 

I've replaced my 91 Extended twice now. Not that hard if the system is original. If yours is truly welded at all points, it may be a replacement system someone has decided to weld up.

For a regular system:Remove the two clamps from the ends of the muffler. Find a suitable chisel or prybar and carefully separate the outer ends of the muffler from the inlet and exit pipes. Spraying the working area with PB Blaster, WD-40, etc will aid in loosening the muffler from the pipes. You will need to peel back the muffler outer ends at least 50% of their length to free the inner pipe from the crimp formed by the muffler clamps. The second time around, I used a hacksaw and CAREFULLY sawed a series of perpendicular slots in the outer ends making it easier to peel back that pipe. It is easy to saw down into the inner pipe so go easy. Yes, keep the heat shield in place when reinstalling.

I replaced my original with a $19.99 cylindrical, universal style (Walker) from AutoZone and the first one lasted around 80,000 miles, the second is still going after 60,000 miles. I drive 50 miles daily round trip to work which allows the exhaust system to thoroughly heat up and dry any condensation in the system. I doubt I would get this kind of longevity on an inexpensive muffler if doing lots of short trips. But, if you wish to save some money, they install easily and are a bargain for the price. Good luck!

 

Aerocolorado,

when you replaced your muffler with the Walker part, did it fit to the flex hose part? When I replaced mine (also with the Walker tube), there was a gap of a few inches to the original flex part. I then replaced the original flex part (gets killed in the same time as the muffler) with a new Walker part and it all fit again. I am now at my 2nd replacement of muffler and flex part.
BTW: the Walker muffler costs around $100 in Germany

Tom
1993 3.0 Ext
Sins, Switzerland

 

whoh... just noticed you are in switzerland! there's aerostars there too??? cool!

 

Hi Tom, good to hear from you again. I recall on the first muffler everything fit properly and it was just a simple swap out. The second time around I just cut the muffler off as close to the body of it as possible, then peeled off the remainder as described above and everything still bolted right up without a problem. I still have my original flex pipe as well as the rest of the exhaust system - only the muffler has been changed. Your European repair experiences have been an eye-opener for all of us back here. Thanks for keeping in touch.

 

Small world My cousin married a German fellow and they now live in Switzerland.

 

Hi Guys,

there's tons of Aerostars in Switzerland. Definitely much more than in Germany, where I lived before. I am currently going through the process of legalizing the van here. Just passed the local smog test, technical inspection is next.

The original muffler was longer (and differently shaped) than the Walker muffler, that's why I had a gap to the flex pipe. Now that both parts are Walker from the same source, they fit (flex pipe is longer). The flex pipe rusts badly at the welding joint between the flex and the rigid part and that's where it breaks every few years, giving the Aerostar a dragster sound

Tom
1993 3.0L Ext.
Sins / Switzerland

 

Tom and others to whom it may concern:
There is a fellow on eBay that is always offering those flex pipes for $36.00. I bought one to have in reserve and it looks like a good product. The hanger is just a bent 1/4" rod rather than the flat steel Ford style but I assume it will go in the rubber mount okay.

 

Where I grew up, we used to hoard foods. Here we're hoarding auto parts Thanks for the info Dave, I'll buy one since it's about that time for one of my Aerostars.

 

Does it improve any extra power or gas/mileage if we change the muffler from single to dual exhausts?

Thank you

 

I didn't realize there were other Aerostar in Switzerland. We vacationed at Lake Como last month and drove up to Lugano and St. Moritz while there. From the looks we got it seemed no one had seen an Aerostar before.

Maybe my customization threw them off

 

True, in the south, you hardly see any. They are more in the central and northern (germanspeaking) parts of the country. But there's less and less every year......
They are crazy about US cars here, much more than the Germans are. Recently there was a meeting of a Cadillac club near my town. On the parking lot, you would see Caddies from the 20s up to their new SUV (whatever it's called). What a sight!

Re flex pipe: this year when I ordered it, it came without the hanger. The hanger is now extra (for extra money)

Tom
1993 3.0 Ext
Sins, Switzerland

 

I would do as my cousin did with his flex pipe when it rotted. Weld in a piece of straight pipe. Oh an to answer the dual muffeler question you would find no power there. The restriction is were the two pipes meet before the catilitic converters and the converters themselves. Exhaust is like plumbing. If there is a restricion in your water flow anything done after the restriction will not make the situation better. Love that icon.

 

Well I sawed off the old muffler and installed the $21 made in USA muffler from Auto Zone. Really was easier than it looked like it was going to be. Instructions say "reinstall heat shield," which must be a joke. I'll have to keep an eye on the floor to see if it gets a little warm, but there is plenty of air between it and the muffler.

John

 

Does the A-Star have the heatshield?
If it does I rather reinstall it since there are many reports about car fire when the vehicles park on grass or so!