OEM Chrysler Voyager Muffler

Chrysler Voyager Muffler Parts and Q&A

• Muffler W/Tpipe
  4881242AG
  Q: How to Service and Repair a Muffler on Chrysler Voyager?

  A:

  Before working on the muffler, use a body contact hoist to raise the car so the unloaded rear suspension makes enough room between the muffler/resonator pipe and the rear axle. Put penetrating oil on the clamp nuts that secure the component you need to remove, but do not apply the oil directly to the flex-joint, since this could destroy the bellows and need you to replace the Catalytic Converter. If your vehicle has AWD, part the right side axle half shaft from the rear differential module and then remove the band clamp from the connection at the muffler to converter pipe. Detach the exhaust hangers on the body screws, pull apart the muffler pipe and the converter pipe and move the muffler/resonator unit forward so that the resonator slides through the rear axle opening. Clean both ends of the tubes or mufflers so that every part matches correctly and get rid of all insulators, rusted clamps, supports and joined parts. Always fit original or equivalent exhaust system parts to maintain correct alignment, acceptable noise, back pressure and acceptable emission and performance levels. After you guide the resonator between the body and rear axle, connect the muffler to the converter but avoid tightening the band clamp, fit the hangers to the body and attach screws starting at the resonator going forward, locking them at a torque of 28 Nm (250 in. lbs.). Make sure the muffler pipe goes into the catalytic converter pipe until the hangers are in the proper place, as overtightening the band clamps may cause the ends of the pipes to bottom out against the center hourglass block, requiring you to change the clamp band. Lift the clamp and remove the nut so you can peel the clamp heads back and let the spot weld break. Then clean away the spot weld and install the new clamp with the same orientation. After that, set the band clamp at 55 Nm (40 ft. lbs.) and connect the right side half shaft to the rear differential module for AWD models only.
• Muffler W/Tpipe
  4881332AH
  Q: How to Maintain and Fix a Muffler on Chrysler Voyager?

  A:

  Before starting the service, lift the car up on a body contact type hoist so its rear suspension weighs nothing on the rear axle and the muffler can be worked on. Try to oil the clamps facing the bellows first, but make sure not to harm or glue them together, as damaging those parts can cause the collect Catalytic Converter to snap and need replacement. Detach the rear differential module from the right side axle half shaft if the car has AWD, then loosen the band clamp on the muffler - to - converter pipe connection. Get rid of the exhaust hangers attached to the body screws, separate the pipes at the converter and muffler and naturally draw the muffler/resonator assembly out of the rear axle. Ensure that the pipes are clean toward the ends so that all components match correctly and throw out any broken or rough insulators, rusted clamps, supports or mounting parts. When updating any exhaust system parts, use either genuine original parts or similar items to make certain there is proper connection, acceptable noise and correct exhaust back pressure. For installation, line up the resonator between the vehicle and the rear axle to fit the muffler/resonator assembly, attach the muffler pipe to the converter pipe so it doesn't get tightened and attach the hangers to the body, beginning with the screws at the resonator and moving forward until they are fixed securely to 28 Nm (250 inch lbs.). Fit the muffler pipe into the catalytic converter pipe, ending when the hangers are in place and make certain not to tighten the clamps, as putting the two pipes together at the center could stretch the clamp, requiring a new replacement band. Removing the nut and disengaging the clamp ends, so the weld breaks, will give you access to the clamp surface; after you remove the old clamp, clean and smooth the weld spot before reinstalling the clamp in the proper way. Next, turn the band clamp to 55 Nm (40 ft. lbs.) and put the right side half shaft back onto the rear differential module if you have an AWD model.