Repairing the muffler on your Ford Windstar more often than not means replacing it. Muffler cases tend to be thin; and if the muffler has damage to it, it is difficult to weld or repair in a way that will keep it from leaking and being potentially unsafe. The muffler on the Windstar sits under the passenger compartment and has both the inlet and outlet pipes on the same end of the muffler. The design looks a little odd but is necessary due to space limitations under the van.
Things You'll Need
- Jack stands
- Socket set
Raise the van with a jack and support it on a set of jack stands. Make sure to place the jack stands under the frame or suspension and check to be sure that the van is stable before you slide under it.
Locate the muffler under the van. Both the inlet and outlet pipes use slip joints and exhaust clamps to attach to the rest of the exhaust system. Remove both clamps with a socket and ratchet.
Locate the two rubber insulators/hangers that secure the muffler to the frame. There is one on the inlet pipe and one on the body of the muffler. Slide the isolators off of the mounting rods that are welded to the muffler then slide the muffler off the exhaust pipes.
Remove the old muffler from under the van and discard it. Raise the new muffler up to the exhaust pipes and slide it onto them. Slide the rubber isolators onto the mounting rods on the muffler and install two new exhaust clamps at the junction of the muffler inlet and outlet pipes with the existing exhaust pipes.
Tighten the nuts on the exhaust clamps with a socket and ratchet. Do not over-tighten the nuts on the clamps, or you will crush the pipe and the system will leak.
Raise the van off of the jack stands with your jack, remove the jack stands from under the van and lower the jack, setting the van on the ground.
- "Haynes Repair Manuals 1995 to 2007 Ford Windstar and Freestar;" Max Haynes; 2010
How to Replace the Muffler on a Ford Explorer
The Ford Explorer is a popular sports utility vehicle with an advanced exhaust system that guarantees maximum performance each time you drive...
How to Replace an EGR Valve on a Ford Windstar
The exhaust gas recirculation (EGR) valve on the Ford Windstar is designed to recycle the vehicle's emissions and burn them off a...
How to Troubleshoot a Ford Windstar DPFE
The differential pressure feedback (DPFE) for the exhaust gas recirculation (EGR) sensor on the Ford Winstar is located in the center of...
How to Remove a Ford Ranger Rubber Exhaust Pipe Hanger
Installing a new exhaust can increase horsepower and the sound output of your vehicle, as well as improve the appearance over the...
How to Remove Rubber Exhaust Hangers
Most modern exhausts feature rubber exhaust hangers that support most, if not all, the weight of a car's exhaust system. Even though...
How to Disable the Alarm on a 2000 Ford Windstar
The Ford Windstar is a mini-van that is no longer manufactured. Ford Windstars from 2000 were optionally equipped with perimeter alarm systems....
How to Troubleshoot the Ford Windstar
The Ford Windstar is a mini-van manufactured by the Ford Motor Company between 1995 and 2003. The Ford Windstar was superseded by...