How to Replace a Muffler

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There are a lot of reasons why you need to replace a muffler on your vehicle. It sometimes becomes clogged with oil particles from the engine or will accumulate rust on the interior parts. Damage to the muffler occurs if the vehicle was driven over an object, causing it to collapse or you punch a hole in the muffler. How it becomes damaged is not as important as the fact that a damaged muffler it will affect the way the vehicle runs and sounds. The good news is that you can replace a muffler on your own, saving yourself money in the process.

Steps

Preparation

1. 1
   Assemble the tools and parts you will need before you begin to replace the muffler.

   
   

   • You will need sockets with a ratchet wrench, a hacksaw or electric reciprocating saw or cutoff tool and a ball peen hammer and wrenches.
   • You also need a vehicle jack and two jack stands to put under the frame while you are under the car, making sure it does not fall. Also, get some wheel blocks to put under the rear wheels.
2. 2
   Gather the parts you need. These will be the muffler appropriate for your vehicle, muffler sealant, 2 exhaust clamps and penetrating oil. Other necessary items are safety glasses and gloves for eye and hand protection.

Removing the Muffler

1. 1
   Park the car on a hard, flat, level surface such as your driveway and begin to remove the muffler.
   • Place the transmission in park and put the emergency brake on.
   • Put the wheel blocks behind the rear wheels to ensure it will not roll.
   • Jack up the front of the vehicle and put a jack stand on each side.
2. 2
   Lower the jack down until the vehicle is sitting on the stands.
3. 3
   Crawl under your car or truck and locate the muffler. It will most likely be in front of the rear wheels and behind the catalytic converter (which is right behind the engine).
4. 4
   Spray penetrating oil on the nuts and clamps to be replaced (liberally) if it is a clamped-on version. There will be two, one each at the front and back of the muffler. Give it a bit of time to do its magic before continuing.
5. 5
   Use deep wall sockets to loosen the muffler clamps.
   • Separate the muffler from the exhaust pipe at the front and rear. This may take some effort, as it could be rusted on tight.
   • Use a hack saw or the electric cut-off tool to cut the exhaust pipe-immediately in front and behind the muffler.
   • Remove the muffler from the hangers holding in place under the vehicle with the muffler free from the exhaust pipe.

Installing the Muffler

1. 1
   Install the replacement muffler by reversing the above steps.
2. 2
   Smooth the ends of the exhaust pipe that connect to the muffler.
3. 3
   Split the ends of the rear section of the exhaust pipe. It needs to be expanded to allow the rear end of the new muffler to slip into the pipe.
4. 4
   Mount the new muffler onto the old hangers.
   • Apply a liberal coat of muffler sealant onto the exhaust pipe at the front of the muffler and on the pipe coming out of the rear of the muffler.
   • Put new muffler clamps onto the ends of the pipe, pushing them out of the way for now.
   • Slip the muffler onto the ends of the exhaust pipe.
   • Move the clamps into place over the connections of the exhaust pipe to the muffler. Tighten them using the deep wall sockets and ratchet wrench.
   • Tighten the nuts so you run them onto the clamps equally on both sides.
5. 5
   Remove the jack stands and lower the vehicle.
6. 6
   Take the wheel blocks away from around the wheels.
7. 7
   Go for a short test drive. When you get back, listen to the exhaust system to make sure that all of the connections are good.

   
   

Tips

• The parts store where you buy your muffler may rent all the tools you will need. Their tools are specifically designed to do the job.
• A cutoff tool looks like a grinder with a thin carbide blade and is a handy electric tool to have in your tool kit. It can be used to cut off rusted bolts, locks and thin-walled metal pipe.
• Inspect the exhaust system after removing the muffler. Make sure it is in good shape. Look for rusted out holes or a pinched exhaust pipe that would inhibit the flow or leak exhaust gases.
• You can get a short section of exhaust pipe that has male and female ends to put the length back as it should be if you cut off too much when replacing the muffler.

Warnings

• Wear eye protection while under the vehicle to protect your eyes from falling debris.
• Be careful when cutting and working on the exhaust system so you do not damage adjacent fuel, electrical and brake lines.

Things You'll Need

• SAE or metric sockets
• Socket wrench
• Ball peen hammer
• Open or combination wrenches -- SAE or metric
• Hack saw, cutoff tool or reciprocating saw
• New muffler
• Exhaust clamps
• Muffler sealant
• Penetrating oil
• Gloves � latex or mechanic's
• Safety glasses
• Vehicle jack
• Jack stands
• Wheel blocks

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