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Home >> Chevrolet >> 2004 >> Astro Van Cargo, AWD >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Muffler Replacement >> Removal Procedure

Removal Procedure

CAUTION: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.
CAUTION: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

An accumulation of dirt and corrosion may make removing exhaust components difficult. Applying a penetrating oil on the threads of the bolts may assist in the removal of these components.

  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Support the muffler assembly.
  3. Remove the 3 nuts connecting the muffler assembly to the catalytic converter assembly.
    Fig 1: Identifying Muffler Flange Bolt Retaining Nuts
    GM84636Courtesy of GENERAL MOTORS CORP.
  4. To aid in the removal of the muffler assembly, lubricate the rubber hangers with rubber lubricant GM P/N 12345884.

    Remove the muffler assembly from the front hanger.

    Fig 2: View Of Muffler Assembly Front Hanger
    GM163857Courtesy of GENERAL MOTORS CORP.
  5. Remove muffler assembly from the rear hanger.
    Fig 3: Locating Muffler Assembly Rear Hanger
    GM475677Courtesy of GENERAL MOTORS CORP.
  6. Remove the muffler assembly from the tailpipe hanger.
    Fig 4: Identifying Muffler Assembly Tailpipe Hanger
    GM163862Courtesy of GENERAL MOTORS CORP.
  7. Remove the muffler assembly from the vehicle.