Muffler and Tailpipe

Muffler and Tailpipe

Removal

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.

All vehicles

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

Vehicles with 2.3L

2. Remove the 2 exhaust downpipe-to-muffler and tail pipe assembly bolts, 2 flagnuts and gasket.
- Discard the flagnuts and gasket.

Vehicles with 4.0L

3. Remove the 2 RH side of the exhaust Y-pipe-to-muffler and tail pipe assembly bolts, 2 flagnuts and gasket.
- Discard the flagnuts and gasket.

All vehicles

4. Disconnect the 3 rubber isolators and remove the muffler and tail pipe assembly.

Installation

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.

NOTE: Clean all the mating surface of the muffler and tail pipe assembly.

All vehicles

1. Position the muffler and tail pipe assembly into the vehicle and connect the 3 rubber isolators.

Vehicles with 2.3L

2. Install a new exhaust downpipe-to-muffler and tail pipe assembly gasket.

3. Install the 2 exhaust downpipe-to-muffler and tail pipe assembly bolts and 2 new flagnuts.
- Tighten to 40 Nm (30 lb-ft).

Vehicles with 4.0L

4. Install a new RH side of the exhaust Y-pipe-to-muffler and tail pipe assembly gasket.

5. Install the 2 RH side of the exhaust Y-pipe-to-muffler and tail pipe assembly bolts and 2 new flagnuts.
- Tighten to 40 Nm (30 lb-ft).

All vehicles

6. Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are not at zero load, carry out the exhaust system alignment procedure. For additional information, refer to Exhaust System Alignment Service and Repair.