THE PORTAL HUB - Pinzgauers, Haflingers, Volvo 303s and more!

I'm about to deal with my exhaust leak at the cylinder head and was wondering if I should know anything special about pulling the header and replacing the muffler. It seems straightforward, but any tips would be appreciated.

If the nuts bind, heat them with a propane or mapp gas torch(they are brass). Avoid breaking off studs

I would only add that the liberal (that's a non-political use of the word) application of a penetrating oil the day before worked for me. I tried heat per Jim's advice, but ended up unscrewing the studs. Compared to breaking them off, this is much preferred.
When you replace the studs, wrap them in Teflon tape. For the next time. And while your in there you should consider installing the flex coupling from SAV. In my case it brought noticeable improvements.

Regarding muffler replacement, I just replaced one on my 710 with one from EI. I sprayed all the bolts and nuts a few times over a few day period with PB Blaster prior to starting on the removal. It came off relatively easily. I found that the heat shield above the muffler had a small hole in it from rust.

Painted the muffler and heat shield with a high-temp paint. The new muffler is noticeable quieter and the truck seems to have more power - might just be imagining that, though!

Thanks everyone. I have what I believe is an EI flex coupler installed already and an EI SS muffler ready to install. I sprayed the nuts and studs with WD40 (all I had laying around in the storage unit). The teflon wrap is only in case the studs thread out from the heads, right? Also, Has anyone built a new header for Pinz's? Seems like a lot of room for improvement there given the uneven runner lengths and 45 angle merges.

Yes, the tape is only if the studs thread out.

McCall, since you have the flex couplers, you may not need to do this: make sure you push the heat exchanger assembly towards the front of the vehicle when tightening the bolt on top. I did not apply enough forward pressure and my couplers are now leaking. You dont want so much that they bind, but you want enough that they dont separate easily.