Exhaust Replacement

[MadTripper]

I guess I need to replace the exhaust on Green Machine. The muffler broke off some time ago and while it's not a big deal because I've been just running it around my place, I want to get it back on the road and I can't do so without fixing this.
So, I think I'll just redo the whole setup. I'm having a little difficulty getting the bolts off where the pipe connects the manifold. Any ideas? Also, is there a common part for the actual muffler?
I'd like to pipe it all the way to the rear but with the aftermarket gas tank back there, I'm not sure I have enough room to do so. Worst case, it exits in front of the right-rear tire like it has been.

Tripper

[bosque]

Those bolts may be the most welded I have run across and had to cut them near flush and drill and tap. Not sure about the muffler but good Q. I have not heard of anyone resourcing them yet.
Good luck, I bet a good muffler shop could do this for what,... under $300? + muffler.?

[azsteve]

I used a blowtorch on my truck a few years ago to get the pipe to manifold bolts moving... kept the heat on until they started to glow, came back after they'd cooled and they finally budged for me. I assume the same might work on the Patrol.

[azsteve]

I used a blowtorch on my truck a few years ago to get the pipe to manifold bolts moving... kept the heat on until they started to glow, came back after they'd cooled and they finally budged for me. I assume the same might work on the Patrol.

forgot to mention that I whacked em a few good times with a sledge once they'd heated up.

[bosque]

Careful....it's cast iron!!!

[MadTripper]

Thanks for the info. Plow Patrol had an exhaust that went to the tail which I liked. When the kiddos and I are cruising through the back 40, the exhaust has a tendency to creep into the cab a little more than I like. We have windows and vents open but you still get the vapors a bit. I'll hopefully get some wrench time in the not so distant future and go from there.

Tripper

[RiverPatrol]

Thanks for the info. Plow Patrol had an exhaust that went to the tail which I liked. When the kiddos and I are cruising through the back 40, the exhaust has a tendency to creep into the cab a little more than I like. We have windows and vents open but you still get the vapors a bit. I'll hopefully get some wrench time in the not so distant future and go from there.

Tripper

This brings up a very good point about exhaust routing, because this can be a dangerous situation. The exhaust end needs to route to the side of the vehicle, not the rear. When it routes to the rear the tailwind billowing brings the exhaust fumes into the vehicle. When the exhaust route out the side of the vehicle the fumes are blown away from the vehicle. I have driven enough Patrols to notice the significant difference. I have one softie that the exhaust routes out the rear, and I hate driving it because the fumes come back into the vehicle. The other softie has the exhaust routed out the side, and I never have the fumes come back into the vehicle, even when driving slow on trails. Togo has the exhaust routed out the rear, but the weatherstripping on the rear doors is fresh and keeps the fumes from coming back in.

Stock there were 2 option; the short exhaust and the long exhaust. The short exhaust ended right after the muffler just in front of the right rear wheel. The long exhaust was routed toe the rear and ended just behind the left rear wheel.

[norville]

I think we should just swap patrols to fix the exhaust issue you're having...


I will be adding a 90 to the PP because of this.. Try soaking the bolts in PB blaster or kroil hit it with a torch , if it brakes, weld on a nut, that will get it real hot.......... shock it with some blaster or wd40..

[miksum56]

Thanks for the info. Plow Patrol had an exhaust that went to the tail which I liked. When the kiddos and I are cruising through the back 40, the exhaust has a tendency to creep into the cab a little more than I like. We have windows and vents open but you still get the vapors a bit. I'll hopefully get some wrench time in the not so distant future and go from there.

Tripper

This brings up a very good point about exhaust routing, because this can be a dangerous situation. The exhaust end needs to route to the side of the vehicle, not the rear. When it routes to the rear the tailwind billowing brings the exhaust fumes into the vehicle. When the exhaust route out the side of the vehicle the fumes are blown away from the vehicle. I have driven enough Patrols to notice the significant difference. I have one softie that the exhaust routes out the rear, and I hate driving it because the fumes come back into the vehicle. The other softie has the exhaust routed out the side, and I never have the fumes come back into the vehicle, even when driving slow on trails. Togo has the exhaust routed out the rear, but the weatherstripping on the rear doors is fresh and keeps the fumes from coming back in.

Stock there were 2 option; the short exhaust and the long exhaust. The short exhaust ended right after the muffler just in front of the right rear wheel. The long exhaust was routed toe the rear and ended just behind the left rear wheel.

Good points all. That is why most vehicles exit to the side behind the rear wheel. Don't recall seeing anyone try this on a Patrol!

[RiverPatrol]

Good points all. That is why most vehicles exit to the side behind the rear wheel. Don't recall seeing anyone try this on a Patrol!

That is actually the stock configuration for the long exhaust option, to exit behind the left rear wheel. That's why there is a bracket there for the exhaust hangar.