This procedure covers the removal and replacement of the muffler assembly on a 2019-2024 Toyota RAV4 with 2.5L I4 FWD engine, including disconnecting exhaust clamps, hangers, and reinstalling with proper torque specifications.

Warnings

Tools required

Parts

• Muffler assembly × 1 — Use OEM specification or quality aftermarket equivalent
• Exhaust gasket (flange) × 1 — 17456-0V010 or equivalent
• Muffler clamps (if reusing is not possible) × 1 — Use OEM specification
• Rubber exhaust hangers (if damaged) × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks in front of front wheels
3. Allow exhaust system to cool completely if vehicle was recently driven
4. Raise rear of vehicle using floor jack at designated rear jacking point
5. Support vehicle securely on jack stands placed at reinforced pinch weld points
6. Spray all exhaust fasteners, clamps, and hanger connections with penetrating oil and allow to soak for 15-30 minutes

Procedure

1. 1

   Inspect exhaust system layout
   From underneath the vehicle, identify the muffler location at the rear of the exhaust system. Note the connection points: flange connection to the mid-pipe (forward of muffler), muffler clamps, and two rubber hangers supporting the muffler assembly. Take photos if needed for reference during reinstallation.
2. 2

   Support muffler assembly
   Place a floor jack or transmission jack under the muffler assembly with a block of wood between the jack and muffler to prevent damage. Raise jack just enough to take weight off the hangers, but do not lift the exhaust system.
3. 3

   Remove muffler clamp
   Locate the band clamp connecting the muffler to the mid-pipe (if equipped with clamp connection rather than flange). Using a 14mm socket, loosen and remove the clamp bolt. If clamp is seized, apply additional penetrating oil and use a wire brush to clean threads. Remove the clamp completely.
   Torque spec

   Muffler Clamps55 Nm (41 lb-ft)
4. 4

   Disconnect flange connection (if equipped)
   If your RAV4 has a flanged connection instead of a band clamp, locate the two flange bolts connecting the muffler to the mid-pipe. Using a 14mm socket, remove both flange bolts and nuts. Note the position of any springs or washers for reinstallation. Remove and discard the old exhaust gasket.
5. 5

   Remove rear rubber hangers
   Locate the two rubber exhaust hangers supporting the muffler assembly (typically one on each side near the rear bumper). Using an exhaust hanger removal tool or flat pry bar, carefully pry the metal hanger rod out of the rubber grommet. Work the hanger free by twisting and pulling. Lower the jack slightly if needed to reduce tension on hangers.
6. 6

   Remove muffler assembly
   With all connections and hangers disconnected, carefully lower the jack and guide the muffler assembly down and out from under the vehicle. The tailpipe will slide out toward the rear. Maneuver carefully to avoid hitting the rear suspension or fuel tank.
7. 7

   Clean connection surfaces
   Use a wire brush to thoroughly clean the muffler mounting surface on the mid-pipe flange or slip joint. Remove all rust, carbon buildup, and old gasket material. Clean the hanger bracket mounting points on the vehicle body. Inspect hanger brackets and tighten if loose.
   Torque spec

   Hanger Bracket Bolts25 Nm (18 lb-ft)
8. 8

   Prepare new muffler for installation
   Unpack the new muffler assembly and verify it matches the original configuration. If using a flanged connection, install the new exhaust gasket onto the muffler inlet flange. Apply anti-seize compound to all flange bolt threads. Check that rubber hangers on vehicle are in good condition and replace if cracked or torn.
9. 9

   Position new muffler assembly
   Place the new muffler on the jack with wood block support. Raise the assembly into position, aligning the inlet connection with the mid-pipe and guiding the tailpipe to exit properly at the rear bumper. Align the metal hanger rods with the rubber grommets on the vehicle body.
10. 10

    Install rear hangers
    Insert the metal hanger rods into the rubber exhaust hangers. You may need to use a pry bar or hanger tool to stretch the rubber grommet over the rod. Ensure both hangers are fully seated. The muffler should hang freely and aligned with the vehicle.
11. 11

    Connect muffler to mid-pipe
    If using a flanged connection, align the flange and install both bolts hand-tight. Ensure the gasket is properly positioned. If using a band clamp connection, slide the clamp over the joint and position it properly. Hand-tighten all fasteners first before final torquing. Verify the tailpipe exits cleanly through the bumper cutout with adequate clearance.
12. 12

    Torque flange bolts or muffler clamp
    Using a torque wrench, tighten the flange bolts to 41 Nm (30 lb-ft) in a cross pattern if equipped with flange connection. If equipped with band clamp, torque the clamp bolt to 55 Nm (41 lb-ft). Double-check that anti-seize was applied to flange bolts.
    Torque spec

    Muffler Clamps55 Nm (41 lb-ft)
13. 13

    Final alignment check
    Remove the support jack from under the muffler. Visually inspect the entire muffler assembly to ensure proper alignment. The tailpipe should be centered in the bumper cutout with at least 1/2 inch clearance all around. Check that no part of the exhaust contacts the body, suspension, or fuel tank. Gently shake the muffler to verify all connections are secure and hangers are properly seated.

Reassembly

1. No disassembly of other components was required for this procedure

Verification

• Lower vehicle from jack stands and remove wheel chocks
• Start engine and allow to idle, listening for any exhaust leaks at the muffler connections
• Have an assistant check the tailpipe outlet while engine is running to verify proper exhaust flow
• With engine at operating temperature, perform a visual inspection underneath for any signs of leaks, contact points, or misalignment
• Test drive vehicle and verify no exhaust rattles, vibrations, or abnormal sounds
• After test drive, re-inspect all connection points for any signs of leakage (black soot marks)

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