Repair And Fix it

Raise the front of your Suzuki off the ground with a jack and position a set of jack stands under the front axle housing to support the vehicle. Make sure the jack stands are on a flat, solid surface, then remove the jack from under the truck.

Locate the flange at the front of the muffler assembly from under the truck. Remove the two mounting bolts from the flange using a wrench on one side and a socket and ratchet on the other.

Move to the rear of the assembly and locate the connection between the tailpipe and the muffler assembly. Remove the nuts from the exhaust clamp on the pipe with a socket and ratchet. Remove the clamp from the exhaust pipe and discard it.

Separate the muffler assembly from the tailpipe, then remove the muffler from the rubber hangers under the truck. Lower the muffler to the ground and remove it from under the truck.

Raise a new muffler assembly into place and connect the two rubber hangers to the support pins on the muffler assembly. Raise the rear of the muffler assembly and slide the tailpipe and the rear connection of the muffler together. Install a new exhaust clamp on the connection and tighten the nuts with a socket and ratchet. Do not over-tighten the nuts or you will crush the pipe.

Position the flange at the front of the muffler assembly against the flange on the front exhaust pipe and install the two retaining bolts. Tighten the bolts with a socket and ratchet on one side and a wrench on the other.

Raise the front of the truck off the jack stands with a jack, remove the jack stands from under the truck, then lower it to the ground.

Prepare the car for muffler removal by jacking it up with a standard car jack or putting it up on car ramps. Since the muffler is located underneath the car, youll have to be able to access that area and move around well enough to do the required work.

Put on protective goggles before starting the actual removal work. A muffler can be rusty, and small chips can easily fly up into your eyes. Goggles will protect them from any debris that might fly around while you do the cutting and prying required to remove the muffler. You may also wish to wear work gloves to protect your hands from cuts.

Lubricate the muffler clamp nut with a coating of penetration oil, and apply the oil to the fittings as well. These parts tend to be dusty and dirty because of their position underneath the car, which exposes them continually to dirt. The oil will make them easier to manipulate and remove.

Remove the nuts that connect the muffler to the exhaust pipes. If the oil does not loosen the nuts well enough to be turned for removal, or if the muffler is welded in place, cut the connecting pipes with your hacksaw. Then, remove muffler nuts from the hanger using your impact wrench. Allow it to drop down so it can be loosened from the rear mounts.

Using the pry bar, complete the removal process by removing the muffler from the rubber straps that are keeping it in place. You can now take the car down from the jack or ramps.

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.

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.

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.

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.

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.

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.

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.

Crawl under the car and check to see if the muffler has a welded installation or a clamped installation. A clamped installation will have bolts that hold the muffler in place. A welded installation will not have any bolts.

Remove the bolts with the screwdriver or wrench if the muffler is clamped on. If you are unfortunate enough to have a welded muffler, purchase an exhaust cutting tool or a blow torch to remove it.

Position yourself under car to replace the muffler. You may want to place a piece of cardboard or an old blanket on the ground so that you are not lying on the ground. You do not need to use jacks to replace the muffler.

Remove the old muffler from the car. You can simply bang it off of the car using a sledge hammer. You can also use a hand saw to remove it if necessary.

Compare the old tail pipe with the new one. You may have to saw off some of the tail pipe so that it closely measures about the same as the old one. You dont want your tail pipe sticking out too far.

Install the new muffler on your Acura Integra. Line it up straight with the clamps and then tighten the bolts to hold it in place. The bolts shouldnt be too tight-you want the muffler to move slightly to prevent damage.