Removal And Installation: Muffler: Installation

All vehicles 

1. If reusing the tailpipe, install a new muffler assembly-to-tailpipe Torca® clamp. For additional information, refer to Torca® Clamp .
2. Position the muffler assembly and connect the rubber isolators.
NOTE: Do not tighten the muffler assembly-to-tailpipe Torca® clamp until the exhaust system has been aligned.
NOTE: Using an abrasive pad, clean the muffler assembly-to-tailpipe surface area of any rust.
3. Position the muffler assembly-to-tailpipe.

Explorer Sport Trac 

NOTE: Install a new muffler inlet pipe service coupler.
NOTE: Using an abrasive pad, clean the muffler inlet pipe service coupler surface area of any rust.
NOTE: If installing a service muffler kit, the coupling will be welded into position on the muffler inlet pipe.
NOTE: The factory muffler inlet pipe will not have an alignment nub.
4. If reusing the factory muffler assembly, position the 2 halves of the muffler inlet pipe into the service exhaust coupler and center the service exhaust coupler onto the cut joint on the muffler inlet pipe. If installing a new service muffler kit, install the muffler inlet pipe coming out of the muffler into the service exhaust coupler.

All Vehicles 

NOTE: Install new exhaust Y-pipe-dual catalytic converter-to-muffler assembly gasket, bolts and nuts.
5. Loosely install the exhaust Y-pipe-dual catalytic converter-to-muffler assembly gasket, bolts and nuts.
6. Align the exhaust system. For additional information, refer to Exhaust System Alignment .