It is easy to replace a muffler. As far as car maintenance goes, muffler replacement is one of the simplest tasks you can undertake, provided the bolts are not rusted in place (however, they usually are). Still, stuck bolts aside, replacing a muffler is major car maintenance that just about anyone with basic mechanic tools should be able to complete without too many complications.
Instructions
Remove the Old Muffler
1. Raise the car. Before you can replace a muffler, you have to be able to get to it. Firmly support the vehicle on a lift, jack stands or ramps. Never get under a car supported only by a jack.
2. Examine your muffler setup. It should be held to the rest of the exhaust system by three or four bolts per pipe. It should attach to the body of the car with rubber muffler hangers.
3. Spray the bolts liberally with a penetrating lubricant, such as PB Blaster. Tap the flanges that hold the bolts a few times with a hammer or wrench to get the lubricant to start working its way into the rust. Let it work for a while. If your bolts are severely rusted, you may need to spray them heavily and let it sit for up to 24 hours.
4. Use your floor jack to raise the muffler enough to reduce tension on the muffler hangers. Then use your hands to pull the hangers off.
5. Unbolt the muffler with ratchets, box wrenches or crow's foot wrenches. If the penetrating lubricant has not work to loosen the bolts, you may need to use a propane torch to release them. If you do need to use a torch, lower the exhaust system as far as possible before you begin applying heat. Carefully heat the bolts with the torch, then immediately try to loosen them. If all else fails, you may need to cut the muffler bolts with a hacksaw.
6. Lower the muffler with the floor jack. Make sure it is balanced so it does not fall on you. Get someone to help you to prevent the muffler from falling onto your face, if possible. The gaskets that seal the two sections of exhaust should fall away. If they do not, tap them with a hammer to remove them.
7. Clean the forward mating surfaces of the exhaust with a rag and automotive cleaner.
8. Loosen the muffler hanger brackets by loosening the bolt that holds them to the main vehicle.
Replace the Muffler
9. Replace a muffler by balancing the new muffler on the floor jack. Raise it until you can fasten it to the forward sections of the exhaust system.
10. Attach the muffler to the forward sections of exhaust with new bolts and nuts. Use a ratchet or wrenches. Be certain not to neglect placing the replacement gaskets in between the two sections of exhaust.
11. Hang the replacement muffler from the body with new exhaust hangers. Simply raise the muffler to the highest level you can with the floor jack, being careful not to crush it against the bottom of the car. Slip the new hangers over the mounting brackets on the muffler itself and on the car body.
12. Lower the floor jack until the muffler is at the desired height. Snug up the muffler hanger brackets by retightening the bolts you loosened in Step 4 of Section 1. The muffler will now be firmly attached to the vehicle.
13. Remove the floor jack. Carefully start the car and check the attachment point for leaks. Move your hand around the attachment points and feel for pulsating air. If you have a leak, check the tension on the bolts. If the bolts are firm, then you probably neglected to reinstall the gaskets properly. Separate the exhaust and try again.
14. Turn the car off, carefully lower it to the ground, and you are done.
Tags: floor jack, sections exhaust, exhaust system, body with, bolts with, exhaust with, forward sections
