1996 Discovery, question about Muffler or Catalytic Converter
 

Hello all,

My 1996 Discovery has been getting louder and louder from under the car. On cold days I see some exhaust coming from under the car.

Does the Discovery have two mufflers or am I looking at the cat converter? Just after the Y pipe there appears to be a muffler and this thing is where my leak is coming from. The pipe going into it is bad.I have to replace this item, can this be a DIY project? There is a joint with 3 bolts which connects it to the Y pipe and another joint just after this item that I would have to disconnect. The bolts on the connectors look to be very rusted, are these usually cut off?

Any suggestions are greatly appreciated.

Thank you.

RE: 1996 Discovery, question about Muffler or Catalytic Converter
 

The Discovery uses 2 catalytic converters, 1 muffler and 1 resonator. What you are looking at is your muffler. The cats are in the branches of the Y-pipe and the resonator is just before the tail pipe

Looking at the RAVE manual the only joint that can be simply unbolted is the on at the Y-pipe. After the muffler it appears to be a solid pipe that would have to be cut and a new muffler welded in.

RE: 1996 Discovery, question about Muffler or Catalytic Converter
 

The exhaust goes like this, left and right exhaust manifolds, left and right cats, then it merges to one exhaust pipe, then muffler then resonator.
The cats are always closest to the engine

RE: 1996 Discovery, question about Muffler or Catalytic Converter
 

Thank you.

Then I need to change the muffler. It does look like it has a clamp just after the Y pipe and another clamp just after the muffler. Sorry I can't figure out how to post with pics. But if you can view the pictures, I tried to show both clamps.



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RE: 1996 Discovery, question about Muffler or Catalytic Converter
 

You may be fortunate if you can get them apart. My 97 only has the bracket in front of the muffler, the muffler, rear section and resonator are all one piece.

What is the white stuff under your rig, is that salt?

RE: 1996 Discovery, question about Muffler or Catalytic Converter
 

I just took my exhaust out... mr sawzall was the only way.

Does anyone know if it is common for the exhaust to separate from the flanges bolted onto the manifolds? Mine did and I need to get those pieces from the junkyard.


I'm gonna get rid of the cats too (1995 FTW)

RE: 1996 Discovery, question about Muffler or Catalytic Converter
 

That white stuff is definitely salt. I live near Chicago.

RE: 1996 Discovery, question about Muffler or Catalytic Converter
 

So if I saw it off, I will need some connecting hardware and of course a muffler. Where should I buy a stock muffler from?

Thank you.

RE: 1996 Discovery, question about Muffler or Catalytic Converter
 

I would worry more about all that salt and the damage it is causing then your muffler. You should power scrub your undercarriage once a month to get rid of that salt before your are driving a rust bucket.
What sort of leak do you think your muffler has?

RE: 1996 Discovery, question about Muffler or Catalytic Converter
 

Just stop by a local muffler shop. Ask for a quote. With as rusty as your pipes are, getting a new muffler to clamp and seal well will be difficult. It needs to be welded in correctly, or you will still have leaks under the truck.

I amso agree with Mike, get that salt off, or you will be rusting through in no time.