Muffler
Muffler
Removal
All vehicles
NOTICE: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger bracket during vehicle operation. Use only water-based lubricants on the isolators.
NOTE: Exhaust fasteners are of a prevailing torque design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Using a suitable jack, support the exhaust system.
4.0L Explorer Sport Trac
3. NOTE: The production muffler assembly is a one-piece design. The service muffler assembly is serviced with 2 pieces.
NOTE: In order to remove the muffler assembly, the muffler inlet pipe must be cut.
Using a suitable exhaust cutter, cut the muffler inlet pipe between the first bend coming out of the muffler and the next bend in line. If a service exhaust coupler is present at this point, loosen the service exhaust coupler nuts and separate the muffler inlet pipe.
4.6L Explorer Sport Trac
4. NOTE: The production muffler assembly is a one-piece design. The service muffler assembly is serviced with 2 pieces.
NOTE: In order to remove the muffler assembly, the muffler inlet pipe must be cut.
Using a suitable exhaust cutter, cut the muffler inlet pipe between the first bend coming out of the muffler and the next bend in line. If a service exhaust coupler is present at this point, loosen the service exhaust coupler nuts and separate the muffler inlet pipe.
All vehicles
5. Loosen the muffler assembly-to-tail pipe Torca(R) clamp.
6. Remove the 2 exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts, 2 nuts and gasket.
- Discard the exhaust Y-pipe dual catalytic converter-to-muffler assembly nuts and gasket.
7. Disconnect the rubber isolators and remove the muffler assembly.
Installation
All vehicles
1. Position the muffler assembly and connect the rubber isolators.
2. NOTE: Using an abrasive pad, clean the muffler assembly-to-tail pipe surface area of any rust.
Position the muffler assembly-to-tail pipe and make sure the tab on the muffler assembly is seated inside the notch on the tail pipe and then tighten the Torca(R) clamp.
- Tighten to 48 Nm (35 lb-ft).
4.0L Explorer Sport Trac
3. NOTE: Using an abrasive pad, clean the muffler inlet pipe service coupler surface area of any rust.
NOTE: If installing a service muffler kit, the coupling will be welded into position on the muffler inlet pipe.
NOTE: The factory muffler inlet pipe will not have an alignment nub.
If reusing the factory muffler assembly, position the 2 halves of the muffler inlet pipe into the service exhaust coupler and center the service exhaust coupler onto the cut joint on the muffler inlet pipe. If installing a new service muffler kit, install the muffler inlet pipe coming out of the muffler into the service exhaust coupler.
4. NOTE: If installing a service muffler kit, the coupling will be welded into position on the muffler inlet pipe.
NOTE: The factory muffler inlet pipe will not have an alignment nub.
If not welded to the muffler inlet pipe, make sure that the service exhaust coupler is against the alignment nub and is positioned approximately at the 2 o'clock position facing the muffler. If the muffler inlet pipe does not have an alignment nub, center the exhaust coupler over the muffler inlet pipe joint and position it at approximately the 2 o'clock position facing the muffler.
- Tighten to 47 Nm (35 lb-ft).
4.6L Explorer Sport Trac
5. NOTE: Using an abrasive pad, clean the muffler inlet pipe service coupler surface area of any rust.
NOTE: If installing a service muffler kit, the coupling will be welded into position on the muffler inlet pipe.
NOTE: The factory muffler inlet pipe will not have an alignment nub.
If reusing the factory muffler assembly, position the 2 halves of the muffler inlet pipe into the service exhaust coupler and center the service exhaust coupler onto the cut joint on the muffler inlet pipe. If installing a new service muffler kit, install the muffler inlet pipe coming out of the muffler into the service exhaust coupler.
6. NOTE: If installing a service muffler kit, the coupling will be welded into position on the muffler inlet pipe.
NOTE: The factory muffler inlet pipe will not have an alignment nub.
If not welded to the muffler inlet pipe, make sure that the service exhaust coupler is against the alignment nub and is positioned approximately at the 2 o'clock position facing the muffler. If the muffler inlet pipe does not have an alignment nub, center the exhaust coupler over the muffler inlet pipe joint and position it at approximately the 2 o'clock position facing the muffler.
- Tighten to 47 Nm (35 lb-ft).
All Vehicles
7. NOTE: Install new exhaust Y-pipe dual catalytic converter-to-muffler assembly gasket and nuts.
Install the exhaust Y-pipe-dual catalytic converter-to-muffler assembly new gasket, 2 bolts and 2 new nuts.
- Tighten to 40 Nm (30 lb-ft).
8. Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are not at zero load, then carry out the exhaust system alignment procedure. For additional information, refer the Exhaust System Alignment Exhaust System Alignment.