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GaryG=> Is having to destroy the muffler to remove it => always a given, or just usually the case? It's certainly *possible* to part the muffler from the rear heat exchangers without destroying either, but it doesn't happen often on unrestored systems. If there's a reason to replace the muffler, it's usually gonna be welded to those HEs, especially in heavy-weather regions. The proper tool can make a positive outcome much more likely. Once in a while you'll see a Type 3 muffler wrench come up on Ebay or someplace, usually for not much money. They're worth having around. Once the exhaust system has been restored and the HE threads properly lubed, it's much easier to deal with this system in maintenance mode. Removing the muffler, relubing those threads and updating the seals for the front exchangers every 25K or so might not be bad policy, even as the muffler is decaying naturally. Steven Ayres, Prescott AZ '66 KG1600 ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ List info at http://www.vwtype3.org/list | mailto:gregm@vwtype3.org