Did your Ford F350 get louder all of the sudden? If you have a rusted out muffler you can save some money by getting the parts at a local parts store and replacing them yourself. If it is the original muffler, it is welded to the extension pipe and the tail pipe at the factory, so you will need to replace all three pieces. Before heading to the parts store, check the rubber hangers that are holding the brackets. If they are torn or dry rotted they will need to be replaced as well.
Instructions
- 1
Park the vehicle on a flat surface. Set the parking brake and chock the wheels. However, you will not need to raise it off the ground because of the height of the F350. Note the position or take a picture of the extension pipe, muffler and tail pipe so you can install the replacement parts in the same position.
2Remove the clamp securing the extension pipe to the catalytic converter pipe with a ratchet and socket. If the nuts on the clamp are rounded or rusted, cut through the clamp's u-bolt with a straight chisel to get it off the pipe.
3Wedge a pipe chisel under the lip of the extension pipe where it is connected to the converter pipe. Split the extension pipe until you can see the end of the converter pipe. The slightly rounded side of the chisel will slide along the converter pipe, while the cutting edge splits the extension pipe as you hit it with a hammer. Split the pipe again 180 degrees from the first split. Cut the extension pipe from the end of the first split to the end of the second split with a hacksaw. Make sure the ends of your splits are past the converter pipe so you don't cut through it.
4Cut the tail pipe off the back of the muffler, using a hacksaw. Pull the brackets attached to the pipes and muffler out of the rubber hangers. The brackets may be rusted in place. Spray them with some rust penatrating oil and work them back and forth until they are loose. Carefully guide the tail pipe over the rear axle so you don't pull on any lines or wires. Clean any rust or debris off of the converter pipe.
5Slide a clamp over the front of the replacement extension pipe and slide it on the converter pipe until it bottoms out. Push the bracket through the rubber hanger. Slide a clamp over the back of the extension pipe. Slide the muffler inlet onto the extension pipe. Push the muffler brackets though the rubber hangers.
6Slide a clamp over the muffler outlet. Guide the tail pipe over the rear axle, again, taking care not to snag it on anything. Slide the tail pipe into the muffler outlet. Push the tail pipe bracket through the rubber hanger. Make sure the extension and tail pipes are inside the muffler enough that they will be sealed by the clamp. If you're not sure, mark the pipes about three inches from the end before installing them and check the marks again before tightening the clamps.
7Tighten the clamps on the extension pipe, muffler and tail pipe until they are difficult to move inside of each other. Adjust the them so they are sitting where the original part were positioned. Check for clearance around the the parts you just installed. You should be able to shake them without contacting any other part of the vehicle.
8Tighten the clamps as tight as you can get them. The ideal tool for this would be an impact gun. But if you don't have one available, some good old fashion elbow grease will work. There should be no movement between the pipes and muffler that you just clamped down. Don't forget to remove the wheel chocks before you try to drive away.
