Muffler: Service and Repair

MUFFLER

REMOVAL

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

1. Raise and support the vehicle.
2. Saturate the clamp nuts with Mopar Rust Penetrant. Allow 5 minutes for penetration.





3. Remove the muffler clamp nuts from the front hanger and the rear muffler to tailpipe connection (Fig. 18).
4. Disconnect the muffler from the tailpipe. The tailpipe should be supported when the muffler is disconnected.
5. Remove the muffler from the extension pipe or catalytic converter flange.

INSTALLATION

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

1. If the upper front muffler support was removed (Fig. 18), install the bolts into the frame. Tighten the bolts to 23 Nm (200 inch lbs.) torque. The insulators slip over the ends of the upper and lower muffler hangers.
2. Install the muffler into the extension pipe or catalytic converter flange. Install the clamp and tighten the nuts finger tight.
3. Install the tailpipe into the rear of the muffler.
4. Tighten the clamp nuts on the front and rear muffler hangers to 41 Nm (30 ft. lbs.) torque.
5. Lower the vehicle.
6. Start the engine, inspect for exhaust leaks. Repair exhaust leaks as necessary.
7. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if necessary.