OEM 2009 Mercury Mountaineer Muffler

2009 Mercury Mountaineer Muffler Parts Q&A

• Q: How to service and repair the muffler on 2009 Mercury Mountaineer?

  A: Service and repair procedures for the muffler must start with placing the vehicle in neutral position and hanging it from a hoist. The exhaust system needs proper support through an appropriate lifting tool. A single-piece structure makes up the production muffler assembly yet the service muffler assembly contains two parts. Begin by cutting the muffler inlet pipe with an exhaust cutter between the first bend coming from the muffler until reaching the second bend. A service exhaust coupler requires you to relax the coupler nuts before separating the inlet pipe from the muffler. Begin by loosening the muffler assembly-to-tail pipe Torca® clamp followed by removing the two exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts during which time the nuts and gasket need discarding. Remove the muffler assembly after disconnecting all rubber isolators. The new muffler assembly should be placed in position after connecting the rubber isolators. Cleaning the muffler assembly-to-tail pipe surfaces for rust requires an abrasive pad but the installation requires seating the tab inside the notch on the tail pipe before you tighten the Torca® clamp to 48 Nm (35 lb-ft). Put together the two pieces of the muffler inlet pipe and position them onto the service exhaust coupler until they center on the cut joint area. New service muffler kit installation requires the muffler inlet pipe to fit into the service exhaust coupler position. To position the service exhaust coupler correctly face its 2 o'clock direction toward the muffler before tightening it to 47 Nm (35 lb-ft). Place the new Y-pipe dual catalytic converter-to-muffler assembly gasket and tighten its nuts to 40 Nm (30 lb-ft). Exhaust system isolators should be at zero-load position before proceeding with the alignment procedure when necessary.