Muffler: Service and Repair

All original equipment exhaust systems are manufactured with the exhaust tailpipe welded to the muffler. Service replacement mufflers and exhaust tailpipes are either clamped together or welded together.

WARNING: If Torches Are Used When Working On The Exhaust System, Do Not Allow The Flame Near The Fuel Line.

CAUTION: When servicing exhaust system components, disconnect the oxygen sensor connector. Allowing the exhaust system to hang by the oxygen sensor harness will damage the wiring and/or sensor.

REMOVAL
1. Raise and support the vehicle.

Fig. 5 Front Exhaust Tailpipe Hanger:

2. Disconnect front tailpipe hanger from the insulator.

Fig. 6 Catalytic Converter To Muffler Connection:

3. Remove the front exhaust clamp from the catalytic converter and muffler connection.
4. Heat the catalytic converter-to-muffler connection with an oxyacetylene torch until the metal becomes cherry red.
5. While the metal is still cherry red, remove the exhaust muffler/tailpipe assembly from the catalytic converter.

Fig. 7 Rear Exhaust Tailpipe Mounting Bracket:

6. Slide the muffler/tailpipe assembly rearward and out of the rear exhaust tailpipe mounting bracket.
7. Remove the muffler from the exhaust tailpipe:
- To remove an original equipment exhaust muffler/tailpipe combination, cut the exhaust tailpipe close to the muffler. Collapse the part remaining in the muffler and remove.
- To remove a service exhaust tailpipe/muffler combination, apply heat until the metal becomes cherry red. Remove the exhaust tailpipe/muffler clamp and twist the exhaust tailpipe out of the muffler.

INSTALLATION
1. Install the muffler onto the catalytic converter. Install the clamp and tighten the nut finger tight.
2. Install the exhaust tailpipe into the rear of the muffler.
3. Install the exhaust tailpipe/muffler assembly on the rear exhaust tailpipe mounting bracket. Make sure that the exhaust tailpipe has sufficient clearance from the floor pan.
4. Install front tailpipe hanger into the insulator.
5. Align the muffler and tighten the nuts on the muffler-to-catalytic converter clamp to 61 Nm (45 ft. lbs.)torque.
6. Align the tailpipe and install a new clamp at the muffler to tailpipe connection.
7. Tighten the muffler to tailpipe clamp to 61 Nm (45 ft. lbs.).
8. Lower the vehicle.
9. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed.