How To: Replace Your Muffler - PartSource: Automotive, Truck Parts & Accessories

How To Replace Muffler

Mufflers are one of the most replaced components for a simple reason: They rust out. This is especially true for us Canadians that spend the winter driving on salted roads, which can speed up corrosion. Even if your muffler is rust free, you may want to replace it with a higher-performing model that will give make your baby really sing. The PartSource Experts are here to help you get the job done in your own garage.

Remember, if you have any questions or if you're unsure of anything, feel free to contact the Parts Pros at your local PartSource. They’ll always ready to help, no matter what the job is.

Let’s go!

Make Safety Your Top Priority

Every vehicle is different. When it comes to maintenance and repairs, always follow the vehicle's owner's manual.

Safety should be your number one priority. Don't smoke, drink alcoholic beverages, or wear a necktie while working on the car. Watch out for hot objects, sharp instruments, hazardous materials and other potential safety hazards in and around your workspace.

Don't work with a Philips when the job calls for a flat. Substituting tools can compromise your safety or your vehicle's performance.

Finally, when the fun turns to frustration, or if the job requires specialized knowledge beyond your capabilities, please do not attempt it yourself. Talk to a Parts Pro or seek the assistance of a professional mechanic or installer. The last thing we want is someone getting hurt.

Before you Begin

Free print outs of vehicle specific instructions and torque specifications are available from MitchellonDemand at your local PartSource. Make sure you have ALL the parts you may need BEFORE you start to work on the exhaust system.


Removing your Muffler

Raise and support vehicle.
IMPORTANT - Always place a safety stand under the raised part of the vehicle. If the vehicle slips off of the jack, it could cause serious injury or death. Always chock any wheels that are not raised off the ground!
If the muffler isn’t welded on, soak any old muffler clamps and joints that will be removed with penetrating fluid.
Loosen muffler clamp bolts and remove old muffler clamps.
If the muffler clamps are rusted to the point the nut can no longer be removed, use a socket and ratchet to twist the nut. This will usually snap the clamp quickly and easily.
Once the muffler clamps are removed, you’ll need to separate the joints. They may easily slide apart, but more likely they will have rusted together and need to be cut.
The same theory applies to the welded exhaust. To cut exhaust, use the cut-off tool in the PartSource Loan-A-Tool exhaust kit #4. In some applications, a hacksaw may be used instead, but the cut-off tool wraps around the exhaust to get in tight spaces, and gives a cleaner cut. Whatever tool you use, don’t cut off more than necessary.
IMPORTANT - Be sure you do not cut any other parts of the vehicle, such as fuel lines, brake lines, wiring, etc.
Remove any hangers still holding the muffler on the car, and then remove the muffler from the vehicle.
Inspect the exhaust pipes that attach to the muffler to make sure that they can be reused. You may need to sand the outside of the pipes where they slide into the muffler, or use the expansion tool in the Loan-A-Tool kit to remove clamp dents.
Now is a good time to inspect other exhaust system parts, like hangers, pipes, catalytic converters, etc.

Installing the New Muffler

Test fit the exhaust together to be sure the parts will slide together snugly.
IMPORTANT - The exhaust parts need to fit securely so you don’t have an exhaust leak. If the parts don’t fit snug together, even clamping them down tighter will not seal it properly, allowing exhaust gases to potentially leak into the cabin of your vehicle.
Reinstall any hangers onto the new muffler.
Coat the exhaust pipe ends with muffler sealant, and slide the parts together. Be sure the muffler is positioned correctly, with the inlet facing the front of the vehicle, and outlet facing the rear. If necessary, use pipe extensions or reducers to help fit or position the new muffler.
Place the muffler clamps, and hand tighten the nuts.
Be sure all exhaust components are positioned correctly, and then tighten the muffler clamps. If necessary, use a jack to hold pipes/mufflers in place while tightening.
Double check that the exhaust is positioned correctly and no exhaust parts are touching other parts of the vehicle including wiring, brake cables, fuel lines and the vehicle body.
Start the engine and check for leaks.
Once you’ve ensured there are no leaks, turn off the vehicle and lower it off the jack stands.
Take the vehicle for a test drive to ensure there is no rattles or leaks from the muffler or exhaust.
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