Front Muffler: Removal

NOTE: The exhaust system is a one-piece construction for production, and two or three piece construction for service exhaust systems.

It is necessary to cut the production exhaust system to enable the service section to be fitted. Before cutting any part of the exhaust system, check the position of the cut is correct in comparison to the service sections to be installed.
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .

CAUTION: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the exhaust flexible pipe.

Fig 1: Supporting Exhaust Flexible Pipe With A Support Wrap Or Suitable Splint

Courtesy of FORD MOTOR CO.

Support the exhaust flexible pipe with a support wrap or suitable splint.
Remove the exhaust flexible pipe-to-muffler assembly nuts.
- Discard the nuts and gasket. Install new studs, if necessary.
Fig 2: Removing Exhaust Flexible Pipe-To-Muffler Assembly Nuts
Courtesy of FORD MOTOR CO.
Detach the tailpipe and muffler assembly from the front exhaust hanger insulators.

Fig 3: Removing Tailpipe And Muffler Assembly From Front Exhaust Hanger Insulators
Courtesy of FORD MOTOR CO.
Cut the exhaust system. For additional information, refer to EXHAUST SYSTEM in Description and Operation portion.
Detach the front muffler from the front exhaust hanger insulator.

Fig 4: Removing Front Muffler From Front Exhaust Hanger Insulator
Courtesy of FORD MOTOR CO.
Detach the front muffler from the rear exhaust hanger insulator.

Fig 5: Removing Front Muffler From Rear Exhaust Hanger Insulator
Courtesy of FORD MOTOR CO.
Remove the muffler assembly.