Removal And Installation: Muffler: Installation

All vehicles 

1. Position the muffler assembly and connect the rubber isolators.
NOTE: Using an abrasive pad, clean the muffler assembly-to-tailpipe surface area of any rust.
2. Position the muffler assembly-to-tailpipe and make sure the tab on the muffler assembly is seated inside the notch on the tailpipe and then tighten the Torca® clamp.
   • Tighten to 48 Nm (35 lb-ft).
Fig 1: Locating Muffler Assembly-To-Tailpipe Torca(R) Clamp And Nut
Courtesy of FORD MOTOR CO.

4.0L Explorer Sport Trac 

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.
3. 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.
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 not welded to the muffler inlet pipe, make sure that the service exhaust coupler is against the alignment nub and is positioned approximately at the 2 o'clock position facing the muffler. If the muffler inlet pipe does not have an alignment nub, center the exhaust coupler over the muffler inlet pipe joint and position it at approximately the 2 o'clock position facing the muffler.
   • Tighten to 47 Nm (35 lb-ft).
Fig 2: Identifying Muffler Inlet Pipe Joint
Courtesy of FORD MOTOR CO.

4.6L Explorer Sport Trac 

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.
5. 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.
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.
6. If not welded to the muffler inlet pipe, make sure that the service exhaust coupler is against the alignment nub and is positioned approximately at the 2 o'clock position facing the muffler. If the muffler inlet pipe does not have an alignment nub, center the exhaust coupler over the muffler inlet pipe joint and position it at approximately the 2 o'clock position facing the muffler.
   • Tighten to 47 Nm (35 lb-ft).
Fig 3: Identifying Service Exhaust Coupler At 2 O'Clock Position
Courtesy of FORD MOTOR CO.

All Vehicles 

NOTE: Install new exhaust Y-pipe dual catalytic converter-to-muffler assembly gasket and nuts.
7. Install the exhaust Y-pipe-dual catalytic converter-to-muffler assembly new gasket, bolts and new nuts.
   • Tighten to 40 Nm (30 lb-ft).
8. Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are not at zero load, then carry out the exhaust system alignment procedure. For additional information, refer the Exhaust System Alignment .