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How Do I Replace the Muffler on a 1998 Dodge 3500 Diesel

The muffler on the 1998 Dodge 3500 Diesel is the main component that prevents the diesel engine running too loud. The exhaust pipe that is attached to the exhaust manifold on the front of the engine travels under the truck and into the muffler. As the sound of the engine travels through the muffler, the baffles inside of the muffler cause the sound to exit in a quieter manner. Over time, the excessive heat that travels through the muffler, will cause the inside of the muffler to rust and not perform properly.

Instructions

1

Park your 1998 Dodge 3500 Diesel on a flat surface and engage the parking brake. Wait one to two hours for the muffler and the exhaust system to cool down.

2

Slide under the rear of the truck and locate the front of the muffler. The exhaust pipe that travels from the engine is mounted to the front muffler port by a metal clamp with two mounting bolts.

3

Saturate the two mounting bolts completely with the rust inhibitor spray or the penetrating oil. Position a socket and a breaker bar onto one of the mounting bolts. Slowly turn the bolt counterclockwise to see how tight the bolt is fastened. If the bolt is still tight, spray more of the rust inhibitor or the penetrating oil on the mounting bolts and repeat the process with the breaker bar and socket until the bolt is loose. Follow the same step with the other mounting bolt. Once the bolts are loose, use a ratchet to finish unscrewing the bolts.

4

Finish loosening and removing the two mounting bolts from the clamp with a ratchet and a socket. Pull the mounting bolts out of the clamp and knock the clamp off of the muffler port with a hammer.

5

Slide the end of a flathead screwdriver into the end of the muffler. Pry the end of the muffler port upward off the exhaust pipe. Make sure the entire front muffler port is pried up off of the exhaust pipe. Try and pull the muffler loose from the exhaust pipe. If the muffler is still stuck, use the hammer to tap the front of the muffler loose from the exhaust pipe.

6

Pull the muffler off the rubber hanger that holds the muffler in place. Slide the muffler out from under the truck. Position the new muffler under the truck and into the rubber hanger.

7

Slide the front port of the muffler over the exhaust pipe. Reconnect the clamp over the exhaust clamp and the muffler with the two mounting bolts. Tighten the bolts down tight with the ratchet and socket. Finish torquing the mounting bolts with the breaker bar and a socket.