Ford Tempo/Topaz 1984-1994 Repair Guide

Special Tools


A number of special exhaust system tools can be rented from auto supply houses or local stores that rent special equipment. A common one is a tail pipe expander, designed to enable you to join pipes of identical diameter.

It may also be quite helpful to use solvents designed to loosen rusted bolts or flanges. Soaking rusted parts the night before you do the job can speed the work of freeing rusted parts considerably. Remember that these solvents are often flammable. Apply only to parts after they are cool!

Inspect inlet pipes, outlet pipes and mufflers for cracked joints, broken welds and corrosion damage that would result in a leaking exhaust system. It is normal for a certain amount of moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler. Inspect the clamps, brackets and insulators for cracks and stripped or badly corroded bolt threads. When flat joints are loosened and/or disconnected to replace a shield pipe or muffler, replace the bolts and flange nuts if there is reasonable doubt that its service life is limited.

The exhaust system, including brush shields, must be free of leaks, binding, grounding and excessive vibrations. These conditions are usually caused by loose or broken flange bolts, shields, brackets or pipes. If any of these conditions exist, check the exhaust system components and alignment. Align or replace as necessary. Brush shields are positioned on the underside of the catalytic converter and should be free from bends which would bring any part of the shield in contact with the catalytic converter or muffler. The shield should also be clear of any combustible material such as dried grass or leaves.

Coat all of the exhaust connections and bolt threads with anti-seize compound to prevent corrosion from making the next disassembly difficult.