1994 Plymouth Voyager Exhaust repair

[quote:cfaf6ce051="pa_hiker"]Engine Mechanical problem
1994 Plymouth Voyager 6 cyl Two Wheel Drive Automatic
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I have to replace the tailpipe on my son's vehicle, but I ran into a problem. The company that replaced the exhaust system welded the tailpipe into the muffler outflow. This brings up two issues:

- the replacement tailpipe seems to be of a size that would fit inside the muffler, I had thought that up-flow pipes always fit inside the down-flow pipe, am I wrong?

- regardless of which is correct, I need to use a pipe expander to widen one of the pipes, how much can you safely expand a pipe?[/quote:cfaf6ce051]

You can safely expand the pipe up to a 1/4"

Thanks. What about the flow direction? Is it safe to maintain the muffler-over-tailpipe fitting?

[quote:4758af4153="pa_hiker"]Thanks. What about the flow direction? Is it safe to maintain the muffler-over-tailpipe fitting?[/quote:4758af4153]

Since the system was welded it didn't matter which way the pipe went on.

Now that you are going to use a clamp you should expand the tail pipe to go over the muffler outlet.

Thanks, that's what I had thought.