hi.. i have a 1997 vw polo and i am currently trying to fit a new back box but having difficultys... is it possible to do it myself?? if so anyone no any ways?? cheers

Edited 13 August, 200719 yr by NATHAN2307

I did it on my mk3 polo, so i would assume it was a fairly similar job.

You really need to get the rear of the car up higher, either on ramps or axle stands. You would be wise to soak the joint where it meets the mid section with some WD40 (or even better, 'PlusGas') to loosen it up a little, for a few days in advance.

Chock the front wheels and put the car in 2nd gear, then get the rears up on stands. It might well help to hit the joint between mid-and rear sections with a soft-headed hammer to loosen it, and remove the clamp if there is one. Just keep waggling the exhaust, hitting it if need be and don't give up til it comes off. If you don't need to re-use the backbox then dont worry about damaging it - when i did mine we snapped off the silencer and manager to use the pipework as a lever against itself...

It might be beneficial to support the mid section with a jack or prop a block of wood against it, to avoid damage further down the system. It will come off eventually, try twisting and waggling and pulling, i needed a mate to help me get it off!

Once it comes off, clean up the jointing face on the mid section with some wire wool and WD40, and apply some exhaust sealing paste before you waggle the new backbox on. Tighten the clamp a fair way, and once the sealant has dried a bit you can tighten it more. Then re-fit the exhaust hangers (its often a good idea to replace these) and away you go! You might find it easier to use a jack to push the exhaust up towards the body mounts, rather than support it yourself.

You did say you were having difficulties - what were you struggling with? Whereabouts are you based mate? If youre in/near leeds you'd be welcome to head to mine and we can give it a try.

WD-40 and a big rubber mallet are your friends. Of all the exhausts I've done I found 6N ones to be the worst for rusting themselves together. Just soak it in WD-40, let it soak in for a bit then just hammer crap out of it till it comes lose. Undo all the rubbers etc and remove the box. If the pipe the back box has just come off is all rusty and what not give it a quick once over with some sandpaper or scotch pad to get rid of the majority of the rust, spray some WD-40 onto it then push it back on. Use the rubber hammer to make sure its on nice and tight. Using a rubber one causes less damage to the new box than using a metal one. Fire the car up to make sure its not blowing, if its not tighten up the clamp properly and jobs a good'un. If its still blowing twist it and hammer it until it stops blowing!

Get a grinder with a cutting disc and slit into it around the join horizontally, 3 or 4 should be enough, obviously not going deep enough to cut into the mid section. Give it a couple of good hammer clouts, twist it and it should come off.

Cheers Guys New Back Box Now on!!... The Height Was The Problem