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:

    Compressor Manifold and Tube Assembly - 3.8L
    Material Item Specification PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN- 12-C) WSH-M1C231- B Removal and Installation NOTE: Installation of a new suction accumulator is not required when repairing the ...

    Dual Converter H-Pipe - 4.6L (2V and 4V)
    Removal NOTE: The RH and LH catalytic converters are serviced separately. 1. Raise and support the vehicle. For additional information, refer to Section. 2. CAUTION: When repairing exhaust system or removing the exhaust components, disconnect all heated oxy ...

    Oil Pan
    Special Tool(s) Compressor, Coil Spring 204-D001 (D78P-5310-A) Lifting Bracket, Engine 303-D088 (D93P-6001-A2) 3-Bar Engine Support Kit 303-F072 Material Item Specification Metal Surface Cleaner F4 ...