How to Change a Muffler in a '99 Chevrolet Malibu

Chevy offered the 1999 Malibu base model with a 2.4-liter four-cylinder engine and an automatic transmission. The muffler is located at the rear of the car and is attached to the bottom of the vehicle by a single hanger. You can clamp a new muffler to the original exhaust piping or weld it to the original exhaust piping if a welder is available. You'll need to cut the old muffler off the original exhaust piping.

Instructions

Removal

1

Park the car on a level surface and set the parking brake. Lift the rear of the car and place the jack stands under the rear suspension frame. Lower the floor jack until the vehicle rests securely on the jack stands. Shake the car to ensure it is safe to work under. Remove the floor jack.

2

Use the hacksaw to cut the muffler off the existing exhaust piping about a half inch behind where the muffler is welded to the piping.

3

Place the pry bar between the upper part of the rubber hanger and the hanger bracket. Support the muffler by hand, and pry the rubber hanger off the hanger bracket with the pry bar. Remove the muffler from under the car.

Installation

4

Install the new rubber hanger onto the hanger rod of the new muffler. Note the arrow on the bottom of the muffler; it should point toward the rear of the vehicle. Lift the muffler into position and press the upper part of the rubber hanger onto the hanger bracket.

5

Swing the muffler toward the rear bumper, and line up the muffler with the exhaust pipe. Push the muffler inlet over the existing exhaust pipe. Set the new tailpipe onto the outlet of the muffler, and tighten the pressure screw with the screwdriver. Line up the exhaust tip with the edge of the rear bumper so the tip does not sit too far forward or behind the bumper.

6

Put on the welding helmet and turn on the welder if you are going to do welding. Place the ground clamp onto the exhaust pipe or muffler and run a weld bead all the way around the muffler inlet and exhaust pipe. Disconnect the welder ground clamp.

7

Place the clamp U-bolt over the muffler inlet tube. Place the bottom clamp bracket over the U-bolt ends and install the U-bolt nuts. Tighten each U-bolt nut with the socket and ratchet until it's tight. The clamp should create a valley that holds the muffler tight to the exhaust pipe and prevents any exhaust leak.

8

Lift the rear of the car off the jack stands with the floor jack, and remove the jack stands. Lower the car to the ground and remove the floor jack.