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How to Replace the Muffler on an Expedition

If your Ford Expedition SUV is making loud noises from the exhaust system, it likely means the muffler has corroded or been damaged. If the muffler has any holes or leaks, you need to replace it. Replacing a muffler is pretty simple, as one is merely bolted to the exhaust system and hanging from the chassis. But you need to get the right muffler for your particular Expedition. You also must safely support the vehicle while off the ground for this installation, as you will be underneath a very large vehicle.

Instructions

1

Raise and support the Expedition on a full jack stand. Dont use the jack included with the vehicle, as it wont safely support the vehicle safely enough for you to go under it. Keep this jack nearby. Locate the bolts attaching the muffler to the exhaust system and the rubber hangers supporting it to the chassis.

2

Lubricate the mufflers bolts with a strong, spray-based lubricant, as they should be very rusty. Wait long enough for the lubricant to work against the rust - heavily rusted bolts may need up to 24 hours.

3

Support the muffler with the Expeditions supplied jack by raising it until the muffler isnt hanging by the rubber hangers. Pull the hangers off the muffler and chassis. Remove the bolts. Lower the jack while balancing the muffler with your free hand to keep it from falling. You may need another persons help.

4

Clean the exhaust systems mating surfaces where the bolts are fastened. Use a good automotive cleaner on a rag. Lightly tap or chip off the gaskets from the bolts if they didnt fall off themselves. Discard them. Loosen the bolts on the brackets for the muffler hangers.

5

Balance the new muffler on the Expeditions jack and raise it until it is barely against the chassis. Bolt the muffler to the exhaust system, using new gaskets with the bolts. Slip new rubber hangers onto the mounting brackets along the muffler.

6

Lower the mufflers jack slightly until the muffler is at the proper height from the chassis. Tighten the bolts on the hanger mounting brackets, then lower the jack the rest of the way and remove it.

7

Start the Expeditions engine while it is still raised on the main jack stand. Carefully feel around the bolts for air pulsating out in the area. If you feel leaking air, check to see if the bolts are tight and the gaskets are properly placed. Lower the vehicle only after the muffler is tightly fastened.