The flange where the muffler connects to the Y pipe is toast. I would rather just replace the muffler and keep the rear section as I don't want to do a complete exhaust. Anyone have a suggestion for an off-the-shelf, not expensive, replacement muffler?

 

I used a Thrush one from Amazon. It was ~$30 I think.

 

Yup, I bought a thrush from AutoZone for like $30 two weeks ago when my clapped out muffler gave up the ghost. I cut off the old muffler leaving some pipe from the flange, used some off the shelf couplers and a few clamps and it went right back together. Think I spent $44 for the muffler, clamps, couplers and a sawzall blade.

 

I'll have to see if I can find a flange that will work as that's what broke on mine. The muffler is still intact, but it won't be for long. I'm not going to own it much longer and don't want to spend a ton on it.

 

Fixed it for free! I removed the old muffler flange, cleaned it up and welded on a section of 2-5/8 exhaust downpipe I had left over from my F250 diesel. One exhaust clamp and no more problem. After I fix a couple of other issues, it might be time to replace the entire exhaust. I guess one can't complain about a 20 year old factory exhaust needing to be replaced...