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How To Replace A Muffler

Whether you’re looking to replace an aging muffler or upgrade to something more high-performance, this easy-to-follow DIY has you covered. 

 

Here’s What You’ll Need:   

  • Jack and Safety Stands
  • Wheel Chocks
  • Socket Set
  • Cut-Off Tool
  • Hacksaw
  • Penetrating Fluid
  • Muffler Cement/Exhaust Sealer
  • Course Sand Paper
  • Application Specific Instructions
  • Muffler
  • Muffler Clamps
  • Exhaust Pipes (As Needed)
  • Exhaust Hangers (As Needed)
  • Pipe Connectors/Reducers (As Needed)

 

Steps for Replacing a Muffler 

Removing the Muffler

1. Raise and support vehicle (see our DIY on How to Jack Up a 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!

2. If the muffler isn’t welded on, soak any old muffler clamps and joints that will be removed with penetrating fluid.

3. 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.

4. Once the muffler clamps are removed, you’ll need to separate the joints. They may slide apart, but they will most likely have rusted together and need to be cut. 

5. The same theory applies to the welded exhaust. To cut the exhaust, use a cut-off tool. In some applications, a hacksaw may be used, 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.

6. Remove any hangers still holding the muffler on the car, and then remove the muffler from the vehicle.

7. 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 an expansion tool to remove clamp dents. Now is a good time to inspect other exhaust system parts, like hangers, pipes, catalytic converters, etc.
 

 

Steps for Replacing a Muffler 

Installing the New Muffler  

1. 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 snugly together, clamping them down tighter will NOT seal them properly. This will allow exhaust gasses to potentially leak into your vehicle's cabin.

2. Reinstall any hangers onto the new muffler.

3. 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 the outlet facing the rear. If necessary, use pipe extensions or reducers to help fit or position the new muffler.

4. Place the muffler clamps, and hand tighten the nuts.

5. Ensure 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.

6. Start the engine and check for leaks.

7. Once you’ve ensured there are no leaks, turn off the vehicle and lower it off the jack stands.8. Take the vehicle for a test drive to ensure there are no rattles or leaks from the muffler or exhaust.