Jeep Wrangler/YJ 1987-1995 Repair Guide

Muffler

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REMOVAL & INSTALLATION



The following applies to exhaust systems using clamped joints. Most later model, original equipment systems use welded joints at the muffler. These joints will, of course, have to be cut.

  1. Raise and support the rear end on jackstands, placed under the frame, so that the axle hangs freely.
  2.  
  3. Remove the muffler clamps.
  4.  
  5. Remove the tailpipe hanger clamp.
  6.  
  7. Spray the joint liberally with a penetrant/rust dissolver compound such as Liquid Wrench®, WD-40®, or equivalent.
  8.  
  9. If the tailpipe cannot be pulled or twisted free from the muffler, drive a chisel between the muffler and tailpipe at several places to free it.
  10.  
  11. Disconnect the muffler hanger.
  12.  
  13. If the pipe leading into the muffler is not to be replaced, and cannot be pulled free of the muffler, heat the joint with an oxyacetylene torch until it is cherry red. Place a block of wood against the front of the muffler and drive it rearward to disengage it from the pipe.
  14.  

If the pipe is being replaced, use a chisel to free it.


CAUTION
When using a torch, make certain that no combustibles, brake or fuel lines are in the immediate area of the torch.

  1. When installing the new muffler, make sure that the locator slot and tab at the tailpipe joint index each other.
  2.  
  3. Drive the muffler onto the front pipe.
  4.  
  5. Position the system, without muffler clamps, under the Jeep and install the hangers. Make certain that there is sufficient clearance between the system components and the floor pan and axle. Then, install the muffler clamps and tighten the hangers.
  6.  

Install the muffler clamps so that the shafts of the U-bolts cover the slots in the joint flanges.

 
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