Ford Mustang (1999-2004) Service Manual: Muffler - 3.8L

Removal and Installation

1. Raise and support the vehicle. For additional information, refer to Section.

2. Support the rear axle with a suitable jack.

3. Remove the upper arm-to-differential bolt.

Muffler - 3.8L

4. Remove the nut and bolt and disconnect the rear shock absorbers (18124) from the axle housing.

  • Discard the nut.

Muffler - 3.8L

5. Lower the rear axle.

6. Remove the dual converter assembly flange nuts.

Muffler - 3.8L

7. Remove the exhaust pipe assembly (5232) from the rear exhaust hanger insulator (5260).

Muffler - 3.8L

8. Remove the exhaust hanger insulators.

Muffler - 3.8L

9. Remove the muffler (5230).

Muffler - 3.8L

10. CAUTION: Do not use oil or grease-based lubricants on insulators as they deteriorate the rubber.

NOTE: A soap-and-water solution will ease installation of the exhaust hanger insulators.

To install, reverse the removal procedure.

    Exhaust System (Diagnosis and Testing)
    Symptom Chart Condition Possible Sources Action Noisy or leaking exhaust Broken or loose clamps, hangers or isolators. Punctures in the muffler ( ...

    Muffler - 4.6L (2V)
    Removal and Installation 1. Use a jack to support and lower the rear axle. 2. Remove the upper arm-to-differential bolt. 3. Remove the nut and bolt, and disconnect the rear shock absorbers (18124) ...

    Other materials:

    Shock Absorber
    Removal WARNING: All vehicles are equipped with gas pressurized shock absorbers which will extend unassisted. Do not apply heat or flame to the shock absorbers during removal or component servicing. Failure to follow these instructions can result in personal ...

    Inspection and Verification
    WARNING: A vehicle equipped with a Traction-Lok differential will always have both wheels driving. If, while the vehicle is being serviced, only one wheel is raised off the ground and the rear axle is driven by the engine, the wheel on the ground could drive ...

    Rocker Arms - Inspection
    CAUTION: Do not attempt to true surfaces by grinding. Check the rocker arm pad, side rails and seat for excessive wear, cracks, nicks or burrs. Check the rocker arm seat bolt for stripped or broken threads. Install new components as ncessary or possible ...