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How to Replace the Muffler on a Ford Explorer

by Contributor

The Ford Explorer is a popular sports utility vehicle with an advanced exhaust system that guarantees maximum performance each time you drive it. The muffler on the Ford Explorer will usually need replaced if it becomes rusted, obtains holes or breaks, or completely falls off the vehicle. It is not very difficult to replace the muffler on the Ford Explorer.

Step 1

Look under the back side of the Ford Explorer to check the muffler for cracks, holes or other breaks. If they are present, you will need to replace the muffler. If there are no holes, breaks or cracks, the muffler is probably not in need of replacement.

Step 2

Purchase a new or used muffler for a Ford Explorer. Make sure the muffler corresponds to the same year as your vehicle. A new muffler is best, but one can sometimes find a good used muffler from a junk yard. The Ford Explorer has a muffler that has a 2.25-inch inlet and outlet diameter, a 4-inch X 9.75-inch X 13-inch case, and a 19-inch over all case length.

Step 3

Place an old blanket or a large piece of cardboard on the ground beneath the rear part of the Ford Explorer. This will permit you to replace the muffler comfortably without lying on the actual ground.

Step 4

Remove the old muffler from the vehicle. Loosen all the bolts that are on top of the muffler strap. Next, pull on the vertical section of the cross member to remove it from the strap and the SUV's exhaust mounting block. Take off the muffler. If the muffler is welded on, then you can break it away by knocking it with a sledge hammer. Dispose of the old muffler properly by breaking it down into small parts and put the small parts into a trash bag.

Step 5

Install the new muffler on your Ford Explorer. Line the muffler straight with the clamps and then tighten the bolts with a wrench to hold it in place. The bolts should not be too tight. The muffler should be able to move slightly to prevent damage.

Start the engine and listen for any loud banging or growling sounds. If there are sounds, you may need to tighten the bolts more or it might not be over the exhaust pipe properly. Check the muffler visually to see if there are any leaks. If there are leaks, you didn't install it properly.


  • Write down the mileage and date of the muffler change and keep this information with the muffler warranty. You may need it for future reference if the muffler breaks or malfunctions.

Items you will need

  • New or used muffler
  • Old blanket or a large piece of cardboard
  • Wrench
  • Sledge hammer
  • Trash bag

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