Muffler Installation

1. Loosely install muffler clamp on 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.





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) and the hanger block. If contact exists, noise will result; so, loosen the muffler strap, shift forward on muffler to eliminate contact, and retighten.

4. Position and tighten the service muffler to ensure that there is 19 mm (3/4 in.) (2) of clearance between the muffler and muffler ramp.

Torque: 22 N.m (16 ft-lbs)





NOTICE:
Locate muffler clamp 25 mm (1.0 in.) (2) from end of muffler inlet pipe and position clamp with U-bolt facing away from fuel tank.

5. Make sure that muffler clamp is properly positioned and aligned. Tighten clamp.

Torque: 41 N.m (30 ft-lbs)

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 muffler block bolt and frame rail to align the hanger parallel with muffler.





6. Check entire exhaust system for proper alignment, clearance to heat shields, and leaks. Muffler body band clamp must be free to move in hanger or vibrations will be transmitted from exhaust system into body. Muffler can be moved both vertically and horizontally in the isolator block. Muffler should move 1/16 in. vertically and 1/8 in. horizontally minimum in the isolator block.