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How to Replace the Muffler on a Chevy Cobalt

by Contributor

Introduced in 2005, the Chevy Cobalt is a compact car meant to replace the Cavalier. To save yourself a little money, you can make some repairs yourself like replacing the muffler. You can choose a new or used muffler, as both are usually affordable. You'll know it's time to replace the muffler when it makes loud banging or shooting sounds when you accelerate. This is usually due to holes or other breaks in the muffler.

Step 1

Verify your Chevy Cobalt needs a new muffler by looking under the car towards the back. The muffler will be a large, round piece at the end of a long pipe. If there are holes in the muffler or if it's missing, you must install a new one.

Step 2

Purchase a new or used muffler. The same muffler will fit all Cobalt models. It should have a 2.25-inch center inlet/outlet. Plus, the width will measure 9.75 inches wide and the length measuring 13 inches long, and it's made from aluminized steel.

Step 3

Place an old blanket or a large piece of cardboard on the ground beneath the rear part of the Cobalt. This will provide a place to lie on the ground as you replace the muffler. It isn't necessary to lift the truck up on a jack or car lift, but it can make it easier to repair.

Step 4

Remove the old exhaust system. Loosen any bolts around the muffler and take the muffler off. If the muffler is welded on, you can trying breaking it free with a sledge hammer if it's already loose; otherwise, use a hacksaw to cut it free.

Step 5

Compare the old muffler against the tail pipe of the new muffler. Saw off some of the new tail pipe with a hack saw, if it's too long. You don't want your tail pipe sticking out too far. Put on the exhaust tip on the end of the pipe.

Install the new muffler on your Chevy Cobalt. Line it up straight with the clamps and then tighten the bolts to hold it in place at the back end of the muffler. Tighten all clamps and bolts around the muffler. The bolts should not be too tight because the muffler needs to move slightly to prevent damage; however, they need to be tight enough to prevent the muffler from falling off.


  • Write down the date and mileage when you replace the muffler. Make sure you store all warranty information in a secure place.
  • Dispose of the old muffler properly by breaking it down into small parts. Put the small parts in a trash bag.

Items you will need

  • New or used muffler
  • Old blanket or piece of cardboard
  • Screwdriver or a wrench
  • Sledge hammer
  • Hacksaw

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