Removal And Installation: Muffler: Installation

NOTE: Install a new exhaust clamp.

Connect the intermediate pipe into the muffler.
Tighten the exhaust clamp.
- The exhaust clamp should be installed so that it is up to, but not over, the bottom of the notches.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 1: Tightening Exhaust Clamp
  Courtesy of FORD MOTOR CO.
Place the new exhaust coupler over the intermediate pipe. Position the intermediate pipe to the catalytic converter, slide the coupler into position until the converter button is seated into the intermediate pipe notch.
Push the muffler forward to fully seat the pipe in the coupler.
- Verify that the intermediate pipe is inserted into the coupler correctly. Correct installation is achieved when the coupler terminates in the knurled region of the intermediate pipe. The knurled section on the intermediate pipe must be at the coupler lip.
  
  Fig 2: Locating Coupler Over Catalyst Pipe
  Courtesy of FORD MOTOR CO.
Tighten the exhaust coupler nuts.
- Tighten to 48 Nm (35 lb-ft).
  - Alternately tighten, in 10 Nm (89 lb-in) increments.