I removed the bolt at the rear of the muffler and it didn't move at all. Does the muffler have to come off to remove the baffle?

 

The muffler has to come off to remove the baffle, go to D&D website, they have instructions for removing the baffle. I soaked mine with WD40 and it slid out easily.

 

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WD 40 each end of the baffle and get a soft pine 2x4. Drop (while holding it so it doesn't fall after the impact) the muffler tip first on the board, the baffle will start to come out. Then use a 2 and a half foot section of 2" pvc to drive out the baffle with a mallet (from the inlet side). If the pipe isn't hot, a 10 minute job max; including removing the muffler.

 

If it is a wrapped baffle it may not come out. they wrap clear tape around the backing and and it acts like clue. D&D will not guarantee that it wont damage the muffler taking it out even if you send it to them...good luck I beat the **** out of one then replaced the muffler with the right baffle....Good Luck

 

If it's been in there a while, it can be a real bastard. I ended up creating a wedge hammer with two 2x2s, then having to burn them apart because they jammed together so hard.

I made a thread about it somewhere.