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Pelican Technical Article:

Rear Muffler Replacement

Nick Czerula

Time:

2 hours2 hrs

Tab:

$200

Talent:

***

Tools:

Set of sockets (13mm, 16mm), pipe cutter, flathead screwdriver, pry bar

Applicable Models:

BMW 525i/xi Sedan (2004-07)
BMW 528i/xi Sedan (2008-10)
BMW 530i/xi Sedan (2004-07)
BMW 530xi Wagon (2006-07)
BMW 535i/xi Sedan (2008-10)
BMW 535xi Wagon (2008)
BMW 545i Sedan (2004-05)
BMW 550i Sedan (2006-10)

Parts Required:

Rear muffler, muffler mounts, exhaust clamps

Hot Tip:

Work with a cool exhaust

Performance Gain:

Replace worn muffler system

Complementary Modification:

Use performance muffler

The exhaust system wears out and becomes leaky with age. A leaky exhaust can be a severe health hazard to passengers if odorless CO or other exhaust gases find their way into the cabin. A leaky exhaust system is usually far noisier than an intact one. Finally, bear in mind that the catalytic converters and oxygen sensors, an integral part of any modern automobile exhaust system, are critical to the emissions control system of the vehicle. Generally speaking, a vehicle with defective exhaust system fails most annual state safety and emissions tests because of the safety hazard, excess noise and emission control failure.

On the BMW E60, you can replace the rear muffler without removing the entire exhaust system. If replacing the front muffler, remove the entire exhaust system as one piece. See our article on removing the exhaust system. Once the exhaust has been removed, repairs or modifications can be made. Keep in mind that a number of other repairs such as drive-shaft replacement, transmission removal and fuel tank removal require that the exhaust system be completely removed from the vehicle.

This article will illustrate how to replace the rear muffler. You can replace your muffler with a stock style muffler or a performance muffler.

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Do not work on your vehicle if you feel the task is beyond your ability.

Vehicle models change and evolve as they grow older, so the vehicle shown in our illustrations may vary slightly from yours. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

Raise and support the rear of the vehicle on jack stands. See our tech article on jacking up your vehicle. Wear those safety glasses while you're working under your automobile.

When replacing the mufflers (red arrows) on your BMW E60, they will come as a pair.
Figure 1

When replacing the mufflers (red arrows) on your BMW E60, they will come as a pair. You will have to cut the pipe in the area of the blue arrow, once you measure the new muffler and make a mark.

Working at the rear muffler, mark the length of the new muffler pipes on the old exhaust system.
Figure 2

Working at the rear muffler, mark the length of the new muffler pipes on the old exhaust system. Raise the new muffler and support it below the old muffler. Align the connection with the old exhaust pipe and mark (red arrow) where you have to cut the pipe. Unlike earlier BMW models, the pipe is cut closer to the center muffler than the rear muffler.

Use a pipe cutter (red arrow) to cut the exhaust pipe.
Figure 3

Use a pipe cutter (red arrow) to cut the exhaust pipe. You can use a saw. However, it is important this cut is straight. If it is crooked, the pipes will not fit inside the clamp properly and the exhaust will not seal. I prefer to use a pipe cutter as it provides a straight even cut.

If your vehicle has a tailpipe flap, disconnect the vacuum hose (green arrow) to the tailpipe flap.
Figure 4

If your vehicle has a tailpipe flap, disconnect the vacuum hose (green arrow) to the tailpipe flap. The flap vacuum hose is located between the mufflers. Working at the muffler, remove the three 13mm exhaust mount fasteners (red arrows). Remove the muffler from the vehicle. Be careful. The pipe (blue arrow) will be sharp.

Pull the chrome exhaust tips off the old muffler and transfer them to the new one.
Figure 5

Pull the chrome exhaust tips off the old muffler and transfer them to the new one. Install the exhaust clamps onto the old exhaust. Then raise the muffler and install the muffler mount fasteners. Do not tighten yet. Slide the clamps so they are half on the old and half on the new exhaust. Tighten the muffler mount fasteners. Align the clamps to bolt the ends point down. Then tighten the clamps. Check the muffler alignment to the body / bumper and adjust it as needed.

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Page last updated: Wed 12/7/2016 02:40:28 AM