Section 09-00: Exhaust System
1994 Mustang Workshop Manual
REMOVAL AND INSTALLATION

Muffler

 WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER ATTEMPT TO SERVICE ANY PART OF THE SYSTEM UNTIL IT HAS COOLED. BE ESPECIALLY CAREFUL WHEN WORKING AROUND THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER ONLY A FEW MINUTES OF ENGINE OPERATION.

 

5.0L Engine

Removal

  1. Remove both rear shock absorbers (18080) at lower rear axle attachments.
  1. Raise vehicle at the frame lift points to allow the axle full downward travel. Refer to Section 00-02. This will provide the clearance necessary to remove and replace the mufflers (5230) .
  1. Remove the muffler to dual converter and pipe connection retaining nuts.
  1. Remove the mufflers from the rear exhaust hanger insulators (5F262) .
  1. Remove the mufflers from the intermediate exhaust hanger insulators .
  1. Slide the muffler rearward to disconnect the muffler from the dual converter and pipe.
  1. Replace any damaged parts.
 

Installation

NOTE: The muffler shields (5290) are clamped to the muffler body. New service clamps must be used for reassembly.

NOTE: For ease of assembly, lubricate exhaust hanger insulators with Silicone Lubricant D7AZ-19553-AA or equivalent meeting Ford specification ESR-M13P4-A prior to installation of muffler .

  1. Position the mufflers over the rear axle assembly (4200) and install into the rear exhaust hanger insulators .
  1. Position the muffler inlet flange to the dual converter and pipe outlet flange. Install but do not tighten the retaining nuts.
  1. Install the intermediate exhaust hanger insulators onto the mufflers .
  1. Align the exhaust system to conform to the proper clearance specifications as shown in the appropriate illustration. Tighten dual converter and pipe to muffler retaining nuts to 29.7-40.3 Nm (22-30 lb-ft).
  1. Assemble both rear shock absorbers to rear axle assembly . Tighten to 79-95 Nm (55-70 lb-ft).

     WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER ATTEMPT TO SERVICE ANY PART OF THE SYSTEM UNTIL IT HAS COOLED. BE ESPECIALLY CAREFUL WHEN WORKING AROUND THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER ONLY A FEW MINUTES OF ENGINE OPERATION.

  1. Check the system for leaks and lower vehicle.
 

3.8L Engine

Removal

  1. Remove both rear shock absorbers at lower rear axle attachments.
  1. Raise vehicle at the frame lift points to allow the axle full downward travel. Refer to Section 00-02. This will provide the clearance necessary to remove and replace the muffler .
  1. Remove the muffler to dual converter and pipe connection retaining nuts.
  1. Remove the muffler from the rear exhaust hanger insulator .
  1. Remove the muffler from the intermediate exhaust hanger insulator .
  1. Slide the muffler rearward to disconnect the muffler from the dual converter and pipe.
  1. Replace any damaged parts.
 

Installation

NOTE: The muffler shield is clamped to the muffler body. New service clamps must be used for reassembly.

NOTE: For ease of assembly, lubricate exhaust hanger insulators with Silicone Lubricant D7AZ-19553-AA or equivalent meeting Ford specification ESR-M13P4-A prior to installing muffler .

  1. Position the muffler over the rear axle assembly and install into the rear exhaust hanger insulator .
  1. Position the muffler inlet flange to the dual converter and pipe outlet flange. Install but do not tighten the retaining nuts.
  1. Install intermediate exhaust hanger insulator onto the muffler .
  1. Align the exhaust system to conform to the proper clearance specifications as shown in the appropriate illustration. Tighten dual converter and pipe to muffler retaining nuts to 29.7-40.3 Nm (22-30 lb-ft).
  1. Assemble both rear shock absorbers to rear axle assembly . Tighten to 79-95 Nm (55-70 lb-ft).

     WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER ATTEMPT TO SERVICE ANY PART OF THE SYSTEM UNTIL IT HAS COOLED. BE ESPECIALLY CAREFUL WHEN WORKING AROUND THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER ONLY A FEW MINUTES OF ENGINE OPERATION.

  1. Check the system for leaks and lower vehicle.