Questions and Answers

Dodge B250 ¾-ton Van Exhaust Work Q. Question on the exhaust system of 1985 Dodge B250 ¾-ton Van, 360 engine.The muffler and catalytic convertor are rusted out. I assume the gizmo ahead of the muffler is the catalytic convertor. Am I right in assuming that this whole exhaust system is held together by the clamps? Can I break this system apart, remove and replace these two units, and just put it back together with these clamps?

My concern is that welding or something unbeknownst to me is involved int the replacement of these parts. I thank you in advance for any information you are willing to supply.

Thank you sir,
Larry

A. Yes, you are correct. The catalytic converter is forward of the muffler. You plan is easier said then done however. First, you will not be able to reuse the clamps. In fact they will, most likely, break when you try to take them off.

After the clamps come off, then the fun begins. After a couple of weeks or so, the clamps don't do anything any more. By then the joints have rusted together and won't easily come apart. Even if they broke loose, they would not come apart because the clamp crimps the pipes together.

At the very least you will need to chisel two slots in the pipe 180° apart so you can work the joints apart. It will take some work to get them apart, but it can be done.

Putting it back together requires a bit of work as well. First tip, don't buy those cheap 1/2" muffler clamps. Spend the extra nickel and get the larger 3/8" clamps. The smaller ones will break.

When you put the clamps on, make sure they are back 2" from the end of the pipe. Then torque them down until the pipes crimp. If they don't crimp, the muffler and catalytic converter will fall off within the first five miles.

A little muffler sealer around the joint will seal the joint completely. I don't care how tight you make the clamps, there will always be a little leakage.