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BMW Rear Muffler Replacement

Pelican Technical Article:

BMW Rear Muffler Replacement

Nick Czerula


2 hours2 hrs






Set of sockets (13mm, E10), pipe cutter, flathead screwdriver, prybar

Applicable Models:

BMW 325i Sedan (2006)
BMW 325xi Sedan/Wagon (2006)
BMW 328i Coupe/Conv (2007-09)
BMW 328i Sedan/Wagon (2007-09)
BMW 330i/xi Sedan (2006)
BMW 335i Coupe/Conv (2007-09)
BMW 335i Sedan (2007-09)

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

You can replace the rear muffler with exhaust installed, but not the center mufflers. This article will illustrate how to replace rear muffler. You can replace your muffler with a stock style muffler or a performance muffler.

Raise and support rear of vehicle on jack stands. See our tech article on Jacking up your vehicle.

If your vehicle has a tailpipe flap, disconnect vacuum hose to tailpipe flap. The flap vacuum hose is located right above the left rear of muffler.

Working at rear muffler, mark length of new muffler pipes on old exhaust system.
Figure 1

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

Use a pipe cutter to cut exhaust pipe.
Figure 2

Use a pipe cutter to cut 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 exhaust will not seal. I prefer to use a pipe cutter as it provides a straight even cut.

Working at muffler, remove E10 mount fastener.
Figure 3

Working at muffler, remove E10 mount fastener. (yellow arrow) Then remove 13mm mount fastener. (green arrow) Remove muffler from vehicle. Install exhaust clamps onto old exhaust. Then raise muffler and install muffler mount fasteners, do not tighten yet. Slide clamps so they are half on old and half on new exhaust. Tighten muffler mount fasteners. Align clamps to bolt ends point down, then tighten clamps. Check muffler alignment to body and adjust as needed.

Comments and Suggestions:
thomnz Comments: Will a 2008 325i m sport muffler/exhaust fit a 2006 320i?
March 21, 2016
  Followup from the Pelican Staff: M likely no. M package, maybe.

You would have to make it work. As the exhaust from the front to rear of the engine is slightly different. - Nick at Pelican Parts
Ai Comments: Will the 07 335i sedan exhaust fit the 07 335xi sedan?? Please help because I'm planning on buy one soon
March 15, 2016
  Followup from the Pelican Staff: Not that I know of. To be sure, Give our parts specialists a call at 1-310-626-8765
- Nick at Pelican Parts
brettdt Comments: Got my left muffler replaced by BMW dealer on my e90 335i. The actuator flap was broken. They mounted the new muffler but the exhaust tip is off center, hanging lower then the original one, and sticking out further. The rear of the car is now noticeably asymmetrical because of this uneven pipe. Will it be possible to adjust his without making a new cut into the exhaust pipe? Possibly just some minor adjustments to the clamps or hanger or something?
January 21, 2015
  Followup from the Pelican Staff: Yes. You should be able to loosen the clamp, adjust the muffler position, then tighten the clamp. - Nick at Pelican Parts  
mohd Comments: hi

bmw 335i e93

i just replaced my car catback by m3 stock catback

i surprised that there is no change in sound nor in performance

please advise

shall i remove the second catback or silincer
December 17, 2013
  Followup from the Pelican Staff: This depends on the parts you used. You may need to remove a resonator to get the sound you seek. - Nick at Pelican Parts  

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Page last updated: Wed 2/21/2018 02:28:16 AM