Muffler

The exhaust system components are removed, disassembled, assembled and installed using standard tools and procedures. Only remove components to the extent necessary to replace worn or damaged components.

Always refer to the Master Parts Catalog for parts usage and interchangeability before replacing a component part of the exhaust system.

Removal

1. Remove U-bolt clamp at the muffler input. On Bronco, disconnect flat flange.

2. Remove the muffler (5230) from the rubber supports at crossmember and frame (5005).

3. Remove muffler. It may be necessary to heat the muffler/converter joint in order to separate the muffler from the catalytic converter.

Installation

1. Place muffler in vehicle by sliding it over axle housing.

2. Position muffler by inserting over the end of the catalytic converter and aligning slot to tab on catalytic converter.

3. Apply a soap solution to metal support rods on muffler and catalytic converter. Avoid use of oils or silicone since they do not dry and may allow the insulator to slip back off once it is installed.

4. Force metal support rods through rubber insulators.

5. Install the U-bolt clamp (U/8500 GVW F-Series/Bronco) and tighten to 54-71 Nm (40-52 lb-ft). On Bronco, install flat flange bolts and tighten to 34-46 Nm (26-34 lb-ft). Tighten nuts sequentially in a criss-cross fashion. Tighten first nut to half torque, then second nut to half torque, then third nut to half-torque, then tighten all nuts to specification.