Exhaust System: Muffler: Installation

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

Insert muffler pipe into catalytic converter pipe until the hangers are positioned as shown in Fig 1

Fig 1: Exhaust System Alignment

Courtesy of DAIMLERCHRYSLER CORP.

1 - HANGER BRACKET TO BODY

2 - ISOLATOR

3 - HANGER - MUFFLER/RESONATOR SUPPORT

4 - 6 mm (0.25 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.

Tighten the band clamp to 55 N.m (40 ft. lbs.). See Fig 2.
Connect the right side half shaft to the rear differential module (AWD equipped only).

Fig 2: Band Clamp
Courtesy of DAIMLERCHRYSLER CORP.

1 - BAND CLAMP

2 - TORQUE SPECIFICATION
Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.