It used to be a lot easier before the days of catalytic converters and resonators and other complicated and integrated exhaust components to repair a cracked muffler pipe. Now the exhaust systems contain many variables that create difficulty when trying to attempt simple repairs. However, with this in mind, the aftermarket exhaust industry has also found some clever ways to work around the complicated systems. If you do indeed have a cracked muffler pipe, you may have some options left before you have to spring out the cash to replace the entire system.
Lift the vehicle safely and securely on a car lift.
Put on the safety glasses.
Locate the cracked muffler pipe.
Put on the welding shield and weld the cracked muffler pipe if the crack is located on a bend in the pipe and a sleeve clamp or buddy sleeve would not be a viable option.
Use the sleeve clamp to cover the crack in the muffler pipe if the crack is small, located on a the seam of the pipe, or if the pipe is broken in a straight section of the muffler pipe. Wrap the clamp around the cracked pipe, place the nut and sleeve brace on the other side of the bolts, and tighten using the ratchet, socket and a hand wrench.
Use a buddy sleeve to reconnect a separated muffler pipe. This would only be an option if the pipe was completely broken in half on a straight section of the muffler pipe. The buddy sleeve would reconnect the two halves of the pipe and you would use to exhaust clamps of suitable size to tighten the buddy sleeve to the cracked muffler pipe.
