Muffler: Service and Repair

REMOVAL





WARNING: Make sure vehicle is properly supported and squarely positioned prior to lifting. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. Make sure hoist does not contact fuel or brake lines.

1. Raise vehicle squarely on a lift.

NOTE: Always use a chain cutter to cut the stainless steel exhaust system pipes. A torch leaves a rough edge and warps the pipe end, preventing good exhaust system sealing.





2. Using chain cutter, cut muffler inlet pipe off next to the weld.
3. Remove muffler strap fastener and muffler.

INSTALLATION
1. Install the proper clamp on the intermediate pipe outlet.





2. Slide the service muffler inlet opening over the intermediate pipe outlet.

NOTE: The intermediate pipe must extend a minimum of 32 mm (1 1/4 inch) into the muffler inlet pipe. The sleeve furnished with each muffler is required when both a service muffler and service intermediate pipe are installed. The sleeve should be retained with the vehicle for possible future use.





3. Install the muffler hanger strap and tighten the clamp. Bumps have been formed in the muffler's sheet metal to locate it squarely in the strap. Torque to 31 Nm (23 ft. lbs.).
4. Check system alignment. Make sure there is no body or shield contact.
5. Position the slip joint clamp 19 mm (3/4 inch) from the muffler's inlet end. Tighten the slip joint clamp, positioned to prevent shield contact. Torque to 31 Nm (23 ft. lbs.).

NOTE: Always use the correct size clamp to prevent exhaust leaks.





6. Check the entire exhaust system for alignment and leaks. The muffler body band clamp blade must be free to move in the hanger or vibrations will be transmitted from the exhaust system into the body. The muffler can be moved both vertically and horizontally in the isolator block. The muffler should move 1/16 inch vertically "A" and 1/8 inch horizontally "B" minimum in the isolator block.

NOTE: If muffler movement cannot be obtained, or muffler isolator block is damaged, the exhaust system will have to be carefully lowered for adjustment or replacement of the muffler isolator block. Washers may have to be installed between the muffler block bolt and frame rail to align the hanger parallel with the muffler. Torque to 25 Nm (19 ft. lbs.).