69 Karmann Ghia original Muffler install...Need help!

[chrisandmeghann]

I am replacing an aftter market muffler with a stock muffler. I have it bolted up but i can not get it to line up with the headers coming off of the engine. The muffle sits about 1/4in above the header. I have tried everything i can think of shy of taking the entire engine apart. Is there a trick to putting the muffler on or should i start further disasembly.

[Marc]

Do you still have stock heat exchangers or have they been replaced with aftermarket J-tubes? It's not at all uncommon for the latter to fit poorly; see if loosening the nuts at #1 & #3 exhaust flanges will allow them to move enough to line up with the new muffler. If a nut doesn't come loose easily, strike it with a chisel (held parallel to the stud) to break it loose rather than risk breaking off a stud.