Muffler: Service and Repair

Muffler and Tailpipe

Exhaust System - Exploded View (Expedition and Navigator Part 1):

Exhaust System - Exploded View (Expedition and Navigator Part 2):

Exhaust System - Exploded View (Expedition EL and Navigator L Part 1):

Exhaust System - Exploded View (Expedition EL and Navigator L Part 2):

Removal

CAUTION: Do not use oil or grease-based lubricants on isolators as they deteriorate the rubber.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.

2. NOTE: LH side shown, RH side similar.

If equipped, remove the transfer case skid plate.





3. Loosen the tailpipe or resonator-to-muffler assembly clamp.





4. Remove the isolator and bracket assembly bolts and remove:
^ the tailpipe for Expedition models.
^ the resonator for Navigator models.





5. Using a suitable jack stand, support the muffler.
6. Remove and discard the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts and flag nuts.

7. CAUTION: Make sure not to make contact with the axle boots while routing the muffler assembly outlet over the rear axle or damage to the boots may result.

Detach the isolators from the muffler assembly and remove from the vehicle

Installation

1. NOTE: Clean the mating surfaces of the exhaust Y-pipe dual catalytic converter-to-muffler assembly.

NOTE: Check the exhaust hanger isolators for wear or damage, install new isolators, if necessary.

Install the muffler assembly into the vehicle and attach the isolators.

2. NOTE: Always install new fasteners.

Loosely install the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts and flag nuts.
3. Install the tailpipe for Expedition models or the resonator for Navigator models and install the isolator and bracket assembly bolts.
^ Tighten to 25 Nm (18 ft. lbs.)





4. Tighten the tailpipe or resonator-to-muffler assembly clamp.
^ Tighten to 48 Nm (35 ft. lbs.)





5. Align the exhaust system.

6. NOTE: LH side shown, RH side similar. If equipped, install the transfer case skid plate.
^ Tighten to 25 Nm (18 ft. lbs.)