How to Install a Muffler on a Car

Road-worthy vehicles must maintain a working exhaust system which includes a muffler for sound diffusion. Cars have mufflers and piping installed at the manufacturer that suppresses most sounds and many impurities that might be produced out the tailpipe. The heart of a quiet, emission-free exhaust system is the muffler. Over time, a muffler will need to be replaced with an original replacement or upgraded to a high-quality performance muffler, which helps an engine produce more horsepower.

Difficulty: Moderately Easy

Instructions

Things You'll Need:

• Muffler Saws-All Muffler pipe bands Ratchet wrench Sockets

1. Raise the car using a car lift to a height that allows for a technician to work under the car easily. Once lifted, the muffler(s) will be visible near the rear of the car. The large, oblong-shaped container within the piping system is the muffler. A muffler may be welded into the exhaust system or it may be secured with pipe straps or U-Bolts. Make a mark on the exhaust pipe 3 inches from each end of the muffler. Measure the distance between the markings to measure the right length to cut out for fitting the new muffler.

2. Remove the old muffler by cutting it out of the exhaust system using the Saws-All with a metal cutting blade attached. Make the cuts vertical to the floor. By making a square cut up and down, the new muffler will fit tightly within the new muffler pipe ends and can be secured tightly with the exhaust pipe straps.

3. Dismantle the remaining tailpipe portion of exhaust tubing from the exhaust system hanger, and set off to the side. By removing the very end of the exhaust tubing, you can install one side of the muffler onto the existing exhaust system and then insert the tailpipe end to finish the job.

4. Slide one end of the new muffler over the existing exhaust tubing with the muffler straps sitting around the expanded end of the muffler inlet tube. Once the existing pipe is seated against the new muffler tubing inlet, begin to tighten the muffler pipe strap to secure the opening around the existing tubing. It is important to maintain the same torque on the muffler strap nuts, and an even tightening will insure a leak-free connection.

5. Insert the tailpipe end of the exhaust tubing into the open outlet of the muffler and re-insert the exhaust hanger hook into the exhaust hanger. With the muffler tubing straps already around the outlet opening, tighten the strap in the same way as the first until it is securely tightened around the existing tailpipe exhaust tubing. With the old exhaust hanger reconnected, the new muffler is properly installed into an existing car exhaust and muffler system.

Tips & Warnings

• Use a torque wrench to properly tighten the muffler tubing straps around the muffler inlet and outlet. Thirty to 35 lbs. of torque is all that is require to secure these types of straps permanently.
• Do not tighten one nut on a muffler tubing strap at a time. If done, it may crease the new or existing exhaust tubing which will create an exhaust leak. Always use the proper torque and procedures for creating a proper seal between mufflers and existing exhaust pipes that are not welded together.

Resources

• QP Muffler Install Slide Show