Muffler: Service and Repair

MUFFLER REPLACEMENT

TOOLS REQUIRED
J 38185 Hose Clamp Pliers

REMOVAL PROCEDURE
1. Remove the rear tires and wheels.




2. Unclip the oxygen sensor connector from the frame.
3. Disconnect the connector position assurance (CPA) retainer.
4. Disconnect the oxygen sensor electrical connector.




5. Remove the exhaust muffler nuts.
6. Loosen the exhaust pipe clamp.
7. With the aid of an assistant, support the exhaust muffler.




8. Remove the insulators from the frame hangers.
9. With the aid of an assistant, slide the muffler rearward in order to remove the muffler from the catalytic converter.
10. Remove the insulators from the muffler hangers.
11. Remove the exhaust manifold pipe gasket.

INSTALLATION PROCEDURE

IMPORTANT: Apply lubricant to the insulators to aid in installation.




1. Install the insulators to the muffler hangers.
2. Install a new exhaust manifold pipe gasket.
3. With the aid of an assistant, slide the muffler forward in order to install the muffler to the catalytic converter.
4. Install the insulators to the frame hangers.




5. Install the exhaust muffler nuts, until snug.
6. Tighten the exhaust pipe clamp bolt and muffler nuts.

Tighten
- Tighten the exhaust muffler nuts to 40 N.m (30 lb ft).
- Tighten the exhaust pipe clamp to 40 N.m (30 lb ft).




7. Connect the oxygen sensor electrical connector.
8. Connect the CPA retainer.
9. Clip the oxygen sensor connector to the frame.