Mazda Trucks 1972-1986 Repair Guide

Special Tools

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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!

COMPONENT REPLACEMENT Exhaust Downpipe



  1. Raise and truck on jackstands.
  2.  
  3. Saturate all bolts and nuts with penetrating lubricant.
  4.  
  5. Disconnect the downpipe from the manifold(s) and discard the seal.
  6.  
  7. Support the catalytic converter and disconnect the downpipe. Discard the gasket, if used.
  8.  
  9. Installation is the reverse of removal. Use new gaskets and seals. Tighten all fasteners to 23 ft. lbs. Make sure that there is sufficient clearance around all parts.
  10.  

Catalytic Converter

  1. Raise and truck on jackstands.
  2.  
  3. Saturate all bolts and nuts with penetrating lubricant.
  4.  
  5. Remove the converter-to-downpipe bolts.
  6.  
  7. Remove the converter-to-muffler inlet pipe bolts.
  8.  
  9. Installation is the reverse of removal. Use new gaskets. Torque the connections to 23 ft. lbs.
  10.  

Muffler

  1. Raise and truck on jackstands.
  2.  
  3. Saturate all bolts and nuts with penetrating lubricant.
  4.  
  5. Remove the converter-to-muffler pipe bolts.
  6.  
  7. Remove the muffler-to-silencer pipe bolts.
  8.  
  9. Remove all muffler hangers and lower the muffler from the truck.
  10.  
  11. Installation is the reverse of removal. Use new gaskets. Torque the bolts to 23 ft. lbs.
  12.  

Silencer and Tailpipe

  1. Raise and truck on jackstands.
  2.  
  3. Saturate all bolts and nuts with penetrating lubricant.
  4.  
  5. Remove the muffler-to-silencer pipe bolts.
  6.  
  7. Remove all silencer hangers and lower the silencer from the truck.
  8.  
  9. Installation is the reverse of removal. Use new gaskets. Torque the bolts to 23 ft. lbs.
  10.  

 
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