Quick answer

Installing a direct-fit muffler kit on your 2005-2009 Subaru Outback is a straightforward bolt-on job that requires basic hand tools, a jack, and about an hour of time.

Why choose a direct-fit muffler kit

A direct-fit muffler kit like the BRExhaust 108-0080 is engineered to match the original factory hangers and pipe routing. That means no cutting, no welding, and no custom fabrication. The aluminized steel construction resists corrosion longer than standard mild steel, which matters if you drive in wet or salty conditions.

The trade-off is that direct-fit kits are model-specific. The BRExhaust 108-0080 fits only the 2005-2009 Subaru Outback 2.5L and 3.0L. If your Outback has a different engine or year, you will need a different part number.

Installation steps

  1. Prepare the vehicle and tools: Park on level ground, apply the parking brake, and loosen the lug nuts on the rear wheels. Jack up the rear of the car and place jack stands under the frame rails. You will need a 12mm and 14mm socket, a breaker bar, penetrating oil, and a rubber mallet. Spray penetrating oil on all exhaust flange bolts and hanger bushings 15 minutes before starting. This prevents snapping a stud.
  2. Remove the old muffler: Unbolt the muffler from the mid-pipe flange (two 12mm or 14mm bolts). Pull the rubber hanger bushings off the metal hanger rods. If the bushings are stuck, use a pry bar or lubricant. Lower the old muffler and set it aside. If a bolt is seized, heat it with a propane torch for 30 seconds before trying to turn it. Do not force it or you may break the stud.
  3. Install the new BRExhaust muffler: Slide the new muffler's hanger rods into the rubber bushings. Align the flange with the mid-pipe outlet. Hand-thread the bolts, then tighten them to 25-30 ft-lbs. Make sure the muffler sits level and does not contact the bumper or underbody. Check clearance at the bumper and spare tire well before final tightening. A rattle means you need to adjust the hanger position.
  4. Test for leaks and final check: Lower the car, start the engine, and listen for exhaust leaks at the flange joint. Run the engine at idle and rev it gently. If you hear a hiss or ticking, tighten the flange bolts slightly. Do a visual check for smoke escaping. A small leak at the flange can be fixed by tightening the bolts another quarter turn. If it persists, the gasket may need replacement.

Product facts