This procedure covers removal and replacement of the muffler assembly on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine.

Warnings

Tools required

Parts

• Muffler assembly × 1 — Use OEM specification or equivalent
• Exhaust flange gasket × 1 — Use OEM specification
• Rubber exhaust hangers (if damaged) — Inspect and replace as needed

Preparation

1. Ensure exhaust system is completely cool to the touch
2. Raise vehicle on lift or support securely on jack stands at all four corners
3. Spray all exhaust fasteners with penetrating oil and allow to soak for 15-30 minutes
4. Visually inspect exhaust system for damage and identify all connection points
5. Ensure adequate lighting under vehicle for work area

Procedure

1. 1

   Support the muffler assembly
   Position a suitable support (jack stand or mechanic's helper) under the muffler to prevent it from falling during removal. The muffler should be supported but not under tension.
2. 2

   Disconnect rear rubber hangers
   Locate the rubber exhaust hangers at the rear of the muffler assembly. Use a prybar or carefully pull the exhaust hanger loops off the mounting brackets. There are typically two hangers supporting the rear of the muffler. Inspect rubber hangers for cracking or deterioration.
3. 3

   Remove muffler inlet flange connection
   Locate the bolted flange connection between the muffler and the intermediate pipe (typically located forward of the muffler near the rear differential). Remove the two flange bolts using a 14mm socket. If bolts are severely corroded, apply additional penetrating oil and use impact tools if available. Separate the flange connection and remove the old gasket.
4. 4

   Remove muffler clamp (if equipped)
   If your specific model uses a band clamp instead of a flange at the muffler inlet, loosen and remove the clamp bolt using a 15mm socket. Slide the clamp off the connection point once the bolt is fully removed.
   Torque spec

   Muffler Clamps55 Nm (41 lb-ft)
5. 5

   Remove muffler assembly
   With all connections and hangers disconnected, carefully lower and remove the muffler assembly from the vehicle. Be prepared for residual water or condensation to drain from the muffler. Inspect all mounting points and hangers on the vehicle for damage.
6. 6

   Clean connection surfaces
   Use a wire brush to thoroughly clean the flange surface on the intermediate pipe where the muffler connects. Remove all old gasket material, rust, and carbon buildup to ensure a proper seal with the new gasket. Clean the exhaust hanger mounting brackets if necessary.
7. 7

   Install new flange gasket
   Position the new exhaust flange gasket onto the intermediate pipe flange. Apply a thin coat of anti-seize compound to the flange bolt threads as specified. Ensure the gasket is properly aligned with all bolt holes.
8. 8

   Position new muffler assembly
   Lift the new muffler into position, aligning the inlet flange with the intermediate pipe connection. Support the muffler at the correct height to align with the rubber hanger mounting points. Do not fully engage hangers yet to allow for adjustment.
9. 9

   Install and torque flange bolts
   Install the flange bolts finger-tight, ensuring the gasket remains properly positioned. Once both bolts are started, torque them in a cross pattern to specification using a torque wrench. Verify the connection is properly sealed with no gaps.
10. 10

    Connect rubber exhaust hangers
    Engage the muffler hanger loops into the rubber hangers and onto the mounting brackets. Use soapy water if needed to ease installation. Ensure all hangers are fully seated and the muffler sits level with proper ground clearance.
11. 11

    Verify alignment and clearances
    Visually inspect the entire exhaust system to ensure proper alignment. Verify there is adequate clearance between the muffler and the rear differential, fuel tank, rear suspension components, and underbody panels. The exhaust should hang straight with no contact points. Adjust hanger positions if necessary.

Reassembly

1. Double-check all connection points are secure and properly torqued
2. Verify all rubber hangers are fully engaged on mounting brackets
3. Ensure no tools or parts have been left under the vehicle

Verification

• Start the engine and listen for exhaust leaks at the flange connection - there should be no hissing or unusual sounds
• With engine running, inspect the flange connection visually for any signs of exhaust gas escaping
• Rev the engine to approximately 2500 RPM and verify no rattling or vibration from the new muffler
• Perform a test drive and listen for any abnormal exhaust noises or drone
• After test drive, re-inspect flange connection while engine is warm for any signs of leakage
• Verify proper ground clearance and that exhaust does not contact any underbody components during suspension travel

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