3-48. MUFFLER AND INSULATOR REPLACEMENT (ALL MODELS EXCEPT M1123 AND
“A2” VEHICLES)
This task covers:
a. Removal
b. Installation
a. Removal
1.
Remove three locknuts (10), washers (9), capscrews (12), and washers (9) from muffler (7) and
crossover pipe (8). Discard locknuts (10).
2.
Remove two nuts (16), lockwashers (15), and U-bolt (13) from muffler (7) and support bracket (14).
Discard lockwashers (15).
3.
Remove gasket (11) by pulling muffler (7) towards rear of vehicle. Discard gasket (11).
NOTE
It may be necessary to lower rear propeller shaft (para 6-5) to
gain access to locknuts on muffler hanger.
4.
Remove four locknuts (3), washers (2), capscrews (6), and washers (2) securing insulator (4) and
retaining plates (5) to muffler hanger (1) and remove muffler (7). Discard locknuts (3).
5.
Remove two locknuts (17), washers (18), capscrews (20), washers (18), insulator (4), and retaining
plate (19) from muffler (7). Discard locknuts (17).
INITIAL SETUP:
Applicable Models
All except: M997A2, M1025A2, M1035A2,
M1043A2, M1045A2, M1097A2, M1123
Tools
General mechanic’s tool kit:
automotive (Appendix B, Item 1)
Materials/Parts
Nine locknuts (Appendix G, Item 106)
Gasket (Appendix G, Item 37)
Two lockwashers (Appendix G, Item 108)
Manual References
TM 9-2320-280-24P
Equipment Condition
Tailpipe removed (para. 3-47).
General Safety Instructions
Do not touch hot exhaust system components with
bare hands.
b. Installation
1.
Install insulator (4) and retaining plate (19) to muffler (7) with two washers (18), capscrews (20),
washers (18), and locknuts (17). Tighten locknuts (17) to 10 lb-ft (14 N•m).
2.
Install muffler (7), insulator (4), and retaining plates (5) to muffler hanger (1) with four washers (2),
capscrews (6), washers (2), and locknuts (3).
3.
Install muffler (7) on bracket (14) with U-bolt (13), two lockwashers (15), and nuts (16).
4.
Install gasket (11) and muffler (7) on crossover pipe (8) with three washers (9), capscrews (12),
washers (9), and locknuts (10). Tighten locknuts (10) to 26 lb-ft (35 N•m).
TM 9-2320-280-20-2
3-88
Change 2
WARNING
Do not touch hot exhaust system components with bare hands.
Severe injury will result.
