My '95 E-300D's rear muffler is making a hell of a racket. There is no hole in it as such, nor is it rusted, it seems however that the inner baffle, or something else, has come loose and is dancing inside the muffler. The noise is very noticeable especially at idle.

Here is the dilemma. The original exhaust system on this car came from the factory with the muffler and resonator as one piece. The replacement units are now available from mercedes only as individual components, meaning I can buy the muffler, or the resonator individually. This is good, however, the resonator on my car is fine, so if I only buy the rear muffler it means that a Muffler shop will need to CUT the flange from the new muffler, as well as cut the existing pipe between the muffler and resonator, then weld on the new rear muffler to the existing resonator. This also means that if I ever need a new resonator, I will need to cut the flange from the new resonator, and then weld it in place.

Alternatively I can buy a new resonator (which I don't need) and a new muffler, have them bolted on and have the job done properly. This last solution is obviously a lot more expensive.

Any advice from a muffler expert out there as to what is the best and cheapest solution. Is welding OK, or am I asking for trouble in the long run? The cost difference is about $250.


Phil

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'95 E300 Diesel, 264,000 Miles. [Sold it]

Back when they built Real Mercedes they were all welded .I say go for it and spend the 250 on some Gold Trim or something.

Some replacement mufflers are designed to be attached with a clamp. Just cut the original pipe with a hacksaw or exhaust pipe cutter, then clamp the new muffler to the pipe. Just be careful not to cut the original pipe too short.

Welding, in my opinion, if done properly is better than a clamp as far as joining two pieces of pipe together that you do not need to seperate.

Go for the welding...your might end up with problems on the clamp in the long run anyway...

Then it must be a miracle that the OE replacement muffler that I clamped on 13 years ago has not fallen off. Just a minute.....let me check to make sure it is still there!!!!

Go try and remove that clamp after 13 years of road grime/rust/etc.



I hate clamps...if I can weld it on it means no problems.

For some..welding is hard or they don't have the means...for others...meh

welding is also sometimes where it rusts first, too.

perhaps depends on the quality of the welding rod.

i like clamps because it facilitates changing the next part to go bad. if put on correctly they wont cause any trouble. make sure they turn the nutted ends to the side and not down. when they are turned down they are perfect for catching the lip on the edge of my trailer when i drive them on.

tom w

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

And catching that occasional piece of road kill...

Opened up a possum one night doing about 80...I tried to dodge him but he doubled back on me and it was a slight blind corner.