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Old 03-14-2003, 09:12 PM
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Join Date: Jan 2003
Location: USA
Posts: 699
Is muffler replacement on a 1981 240D a DIY job?

Dear friends:

I wonder whether replacing the front exhaust pipe, center muffler (resonator?) and rear muffler is a DIY job? Do I need a welder or something?

Thank you very much for your precious help.

Best regards,

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Old 03-14-2003, 09:22 PM
MS Fowler's Avatar
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Join Date: Jan 2003
Location: Littlestown PA ( 6 miles south of Gettysburg)
Posts: 2,209
In my experience, exhaust work is just dirty; not difficult. Everything is bolt-on. The only real problem may be the bolts to the manifold. You can try pre-lubing them with some prenetrating oil for a few days prior to doing the whole system. You can even try to get these bolts moving ahead of time. If they start to twist without unscrewing stop, or you'll twist them off. If they begin to unscrew, just retighten them until you are ready to replace the system. I wouldn't bother trying to unbolt anything else--just take a hack saw and cut the system into easy-to-handle pieces. Wear eye protection, did I mention that exhaust work is dirty?
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Old 03-14-2003, 09:41 PM
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Thank you very much MS Fowler. Your post is very informative.

Best regards,

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Old 03-15-2003, 07:59 AM
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Join Date: May 2000
Location: Soperton, Ga. USA
Posts: 11,243
On this vehicle it is most definitely a diy'er operation. Like MS Fowler said - try some penetrating oil on the fasteners first then if that don't work just cut them off. If they are studs that will be re-used you may need to heat the nut up somewhat to remove them.
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