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 the isolators. These lubricants may cause deterioration of the isolator. This can lead to separation of the isolator from the exhaust hanger bracket during vehicle operation.

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 Torca(R) 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 jackstand, support the muffler.
6. Remove the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts and 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

CAUTION: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause deterioration of the isolator. This can lead to separation of the isolators from the exhaust hanger bracket during vehicle operation.

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. Install the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts and tighten in the following sequence:
1 Snug the outer exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt.
2 Tighten the inner exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt.
^ Tighten to 63 Nm (46 lb-ft).
3 Tighten the outer exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt.
^ Tighten to 63 Nm (46 lb-ft).
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 lb-ft).





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





5. Check to see if the exhaust system isolators are a zero load. If the exhaust system isolators are not at zero load, then carry out the exhaust system alignment procedure.

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

If equipped, install the transfer case skid plate.
^ Tighten to 25 Nm (18 lb-ft).