Repairing the muffler on your Ford Windstar more often than not means replacing it. Muffler cases tend to be thin; and if the muffler has damage to it, it is difficult to weld or repair in a way that will keep it from leaking and being potentially unsafe. The muffler on the Windstar sits under the passenger compartment and has both the inlet and outlet pipes on the same end of the muffler. The design looks a little odd but is necessary due to space limitations under the van.
Raise the van with a jack and support it on a set of jack stands. Make sure to place the jack stands under the frame or suspension and check to be sure that the van is stable before you slide under it.
Locate the muffler under the van. Both the inlet and outlet pipes use slip joints and exhaust clamps to attach to the rest of the exhaust system. Remove both clamps with a socket and ratchet.
Locate the two rubber insulators/hangers that secure the muffler to the frame. There is one on the inlet pipe and one on the body of the muffler. Slide the isolators off of the mounting rods that are welded to the muffler then slide the muffler off the exhaust pipes.
Remove the old muffler from under the van and discard it. Raise the new muffler up to the exhaust pipes and slide it onto them. Slide the rubber isolators onto the mounting rods on the muffler and install two new exhaust clamps at the junction of the muffler inlet and outlet pipes with the existing exhaust pipes.
Tighten the nuts on the exhaust clamps with a socket and ratchet. Do not over-tighten the nuts on the clamps, or you will crush the pipe and the system will leak.
Raise the van off of the jack stands with your jack, remove the jack stands from under the van and lower the jack, setting the van on the ground.
