Muffler: Service and Repair

MUFFLER AND TAILPIPE

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.

WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE FLAME NEAR THE FUEL LINES.

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

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.

REMOVAL
1. Raise the vehicle and support the rear of the vehicle by the side rails and allow the axle to hang free.






2. Remove the clamp from the catalytic converter and muffler connection.






3. Remove the tailpipe hangers from the insulators .
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, twist the exhaust tailpipe/muffler assembly back and forth to separate it from the catalytic converter.
^ To separate an original equipment exhaust tailpipe/muffler 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. Assemble catalytic converter and muffler loosely to permit proper alignment of all parts.
2. Install the exhaust tailpipe into the rear of the muffler.
3. Install the exhaust tailpipe/muffler assembly on the rear exhaust tailpipe hanger. Make sure that the exhaust tailpipe has sufficient clearance from the floor pan.
4. Tighten the nut on the muffler-to-catalytic converter clamp to 48 Nm (35 ft. lbs.) torque.
5. Insert rods into isolators.
6. Lower the vehicle.
7. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed.