Muffler: Service and Repair

REMOVAL
1. Raise vehicle on a body contact type hoist.

NOTE: To provide removal clearance between muffler/resonator pipe and rear axle parts, the rear suspension must be relieved of all body weight.

2. Apply a penetrating oil to clamp nuts of component requiring removal.

CAUTION: When servicing the exhaust system, care must be exercised not to dent or bend the bellows of the flex-joint. Should this occur, the flex-joint will eventually fail, requiring replacement of the catalytic converter.

3. Disconnect the right side axle half shaft from the rear differential module (AWD equipped only).

Fig.10:

4. Loosen the band clamp at the muffler to converter pipe connection.
5. Remove the exhaust hangers to body screws.
6. Separate muffler pipe from converter pipe.
7. Remove muffler/resonator assembly by moving assembly forward and guiding the resonator through the rear axle to body opening.
8. Clean ends of pipes or muffler to assure mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts. When replacement is required on any component of the exhaust system, it is important that original equipment parts (or equivalent) be used for the following conditions:
- Ensure proper alignment with other components in the system.
- Provide acceptable exhaust noise levels.
- Provide proper exhaust system back pressure for maintaining emission and performance levels.

INSTALLATION
1. Install the muffler/resonator assembly by guiding resonator between the rear axle and body.
2. Connect the muffler pipe to the converter pipe but do not tighten band clamp.
3. Position hangers to body and install screws starting at the resonator working forward. Tighten hanger screws to 28 Nm (250 in. lbs.).

Fig.11:

4. Insert muffler pipe into catalytic converter pipe until the hangers are positioned as shown in

CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block. Once this occurs, the clamp band has been stretched and has lost its clamping force and must be replaced.

To replace the band clamp; remove the nut and peel back the ends of the clamp until spot weld breaks. Clean remaining spot weld from the pipe using a file or grinder until surface is smooth.

NOTE: Maintain proper clamp orientation when replacing with new clamp.

Fig.12:

5. Tighten the band clamp to 55 Nm (40 ft. lbs.).
6. Connect the right side half shaft to the rear differential module (AWD equipped only).