Muffler: Service and Repair

^ Tools Required
- SA9168NE Exhaust and Tailpipe Cutter


Removal

CAUTION: 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.

NOTICE: If the entire intermediate pipe and muffler assembly is being replaced, the service intermediate pipe must be shortened at the outlet end. Cut the intermediate pipe right behind the up-sized outlet end.





1. Raise vehicle squarely on a lift.

NOTICE: Always use a chain cutter to cut the stainless steel exhaust system pipes.





2. Using chain cutter SA1968NE (or equivalent), cut intermediate pipe in front of the rear suspension. Locate center O of the approximately 100 mm (4.0 inch) long straight section, mark the pipe, and make cut.
3. Remove muffler strap fastener and muffler.

Installation





1. Loosely install muffler clamp over service replacement muffler inlet
2. Load replacement muffler to vehicle, sliding muffler inlet pipe over cut section of intermediate pipe.
3. Hold muffler in location to muffler strap and tighten clamp. Locate muffler strap between stamped channel in the muffler.
Torque: 22 Nm (16 ft. lbs.)





IMPORTANT: Make sure that after installing the replacement exhaust sections that the system has not shifted rearward allowing contact between the hanger bracket screw (1) the hanger block. This will cause noise; loosen the muffler strap and shift forward on muffler to eliminate contact - retighten.

Torque: 22 Nm (16 ft. lbs.)

NOTICE:
^ Position the muffler to ensure that there is 19 mm (3/4 inch) of clearance between the muffler and muffler ramp. If proper clearance can not be obtained, the intermediate pipe must be shortened.
^ Locate muffler clamp 25 mm (1.0 inch) A)) from the end of the muffler inlet pipe and position clamp with U-bolt facing away from fuel tank.





4. Make sure muffler clamp is properly located and aligned; tighten clamp.
Torque: 41 Nm (30 ft. lbs.)





5. Check the entire exhaust system for alignment, clearance to heat shields, 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.

IMPORTANT: 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.

6. Tighten muffler isolator block.
Torque: 25 Nm (19 ft. lbs.)