Kerker Muffler Disassembly

[Mashermoto]

I bought a Kerker 4-1 off Ebay knowing it was in bad shape. Now I'm trying to salvage it for my build. The baffle is either stuck really tight or I'm going at the removal wrong. Below is what I have.



My first thought was that this black pipe extending out of the inlet side could be pushed out the outlet side. It won't budge.



This is the muffler I want to remove. The bolt holding it in has been removed...actually twisted off as the threads are rusted in as well.



As you can see the muffler is really rusty

So...does anyone know how the muffler is constructed

[DiverRay]

You will have to drill out the bolt, as ANY threads that stick up will hold the part in.The baffle DOES come out the outlet side. I would use PB Blaster around the back part, to free it up. The reverse cone is ALUMINUM so be very careful with it!
Once the part has soaked for about 20 minutes, put a block of wood on the ground, hold the outside of the muffler, and bang the pipe that sticks out the front on the wood. This should drive the cone out the back of the muffler. You may want to try and sand the inside of the muffler so the cone has a smooth way out.

[Mashermoto]

I'll give it a try and let you know the results.

Thanks!

[bikerphil]

On a Kerker pipe I have, the baffle comes out the inlet side and the rear cone stays in place. They do tend to get stuck pretty good if they have never been removed. IIRC, I had to put the baffle pipe at the inlet end somehow in a vise, and hammer the can away from the vise. I never needed to remove that cone piece in the back. HTH

[oldyam80sg]

That's a shame to look at. My Kerker is not brand spanking new but obviously someone didn't care for it that much!

[Da-Bubble]

Well that proves that my Kerker has been thoroughly hacked up. Mine looks nothing like that when disassembled. Mine doesn't even have a cone, just a flat plate with a hole in the center and "custom" drilled holes around the outside. Did they make more that one style? Mine also doesn't have a pipe protruding from the inlet side.

[mxmikie]

i had to use a slide hammer to get mine out

[03mach1]

Same as mine, I think some of my baffles, insulation is missing too.

I used the Hi Temp Satin Black (eastwood co.) on mine and on the headers and holding up really well.

[EricHa]

DiverRay's method worked for me. I used penetrating oil on the baffle cone, letting a small puddle sit for a couple of days, then rapped the exposed baffle end on a piece of wood until it broke free.

[GaryF]

Da Bubble
your pipe looks more like the mac on my sf

I have the kerker on my sh and it is more up swept than the mac although
the megaphones look alike
mine is on the left

Masher drill out that bolt and push from the inlet it will come right out

[Mashermoto]

Well...It's been soaking in PB Blaster for a full day now but no movement. I'll let it soak until tomorrow night and then pound it into submission

How did you guys use slide hammers?

[GaryF]

When you start pounding from the bottom and the aluminum cone starts to show itself don't pull on it or it will separate from the baffle and you'll have a hell of a time getting it back together
I'm speaking from experience
I tried everything from gorilla glue to running just the cone without a baffle
finally using JB WELD

[bikerphil]

This is my early 80's Kerker. Baffle comes out the front. This one doesn't have the Kerker emblem like most others, it's just stamped Kerker on the mounting bracket. It has a 2 1/2" inlet instead of 2 1/4".

[Mashermoto]

Take a look at my second picture that shows the small diameter pipe inside the larger diameter pipe. Does anybody's muffler look like that?

[oldyam80sg]

Mine does.I never have replaced anything inside of it.Still sounds like day 1.