Explorer 2WD V8-4.6L (2008)
All vehicles
5. Loosen the muffler assembly-to-tailpipe Torca(R) clamp.
6. Remove the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts, nuts and gasket.
^
Discard the exhaust Y-pipe dual catalytic converter-to-muffler assembly nuts and gasket.
7. Disconnect the rubber isolators and remove the muffler assembly.
Installation
All vehicles
1. Position the muffler assembly and connect the rubber isolators.
2. NOTE: Using an abrasive pad, clean the muffler assembly-to-tailpipe surface area of any rust.
Position the muffler assembly-to-tailpipe and make sure the tab on the muffler assembly is seated inside the notch on the tailpipe and then tighten
the Torca(R) clamp.
^
Tighten to 48 Nm (35 lb-ft).
4.0L Explorer Sport Trac
3. NOTE: Using an abrasive pad, clean the muffler inlet pipe service coupler surface area of any rust.
NOTE: If installing a service muffler kit, the coupling will be welded into position on the muffler inlet pipe.
NOTE: The factory muffler inlet pipe will not have an alignment nub.
If reusing the factory muffler assembly, position the 2 halves of the muffler inlet pipe into the service exhaust coupler and center the service
exhaust coupler onto the cut joint on the muffler inlet pipe. If installing a new service muffler kit, install the muffler inlet pipe coming out of the
muffler into the service exhaust coupler.
4. NOTE: If installing a service muffler kit, the coupling will be welded into position on the muffler inlet pipe.
NOTE: The factory muffler inlet pipe will not have an alignment nub.
If not welded to the muffler inlet pipe, make sure that the service exhaust coupler is against the alignment nub and is positioned approximately at
the 2 o'clock position facing the muffler. If the muffler inlet pipe does not have an alignment nub, center the exhaust coupler over the muffler inlet
pipe joint and position it at approximately the 2 o'clock position facing the muffler.
