Removal and installation of main and additional mufflers (Mondeo 4)

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The main and additional mufflers are connected to each other by welded pipes into a non-separable unit, which, if any element is damaged, must be removed from the vehicle as a whole.

You will need: a 13 mm wrench and a flat-blade screwdriver.

You will need: a 13 mm wrench and a flat-blade screwdriver.


1. Unscrew the nuts…

1. Unscrew the nuts…


2….and disconnect the flanges of the exhaust manifold and the additional muffler (see Removing and installing the catalytic converter and replacing its gasket).

2….and disconnect the flanges of the exhaust manifold and the additional muffler (see Removing and…


3. Remove the cushions from the brackets at the rear of the main mufflers and then remove the main and additional mufflers from the vehicle.



NOTE: The front main muffler suspension cushion was removed from its bracket before separating the exhaust manifold and sub-muffler flanges (see item 1).


4. Install the main and additional mufflers in the reverse order of removal. Be sure to replace the sealing gasket between the flanges of the exhaust manifold and the additional muffler with a new one. To facilitate the installation of the suspension cushions of the system, lubricate the brackets of the main muffler and exhaust pipe with a soap solution.

NOTE: The spare parts can be supplied separately as main and additional mufflers with pipes…


NOTE: The spare parts can be supplied separately as main and additional mufflers with pipes…


…moreover, the pipes may have flared ends of increased diameter for telescopic connection or not have flared ends for butt connection.

…moreover, the pipes may have flared ends of increased diameter for telescopic connection or not…


In both cases, to replace the damaged element, it is necessary to cut the pipe connecting them on site, for example, with a flat grinder ("Bulgarian"), placing a new element nearby to determine the place of the cut. Moreover, for a telescopic connection, it is necessary to cut the pipe with a margin necessary for inserting the old pipe into the new one, and for a butt joint - without a margin. In the first case, the pipes are connected with clamps, and in the second - by welding or a transition coupling.

(The original version can be found on the website FordBook)






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