REMOVAL
3.7L ENGINE
WARNING: If torches are used when working on the exhaust system, do not allow the flame near the fuel lines.
1. Raise and support the vehicle.
2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
3. Remove transmission crossmember (Refer to 13 - FRAME & BUMPERS/FRAME/REAR CROSSMEMBER - REMOVAL).
4. Disconnect and mark oxygen sensor electrical connectors.
5. Remove steady rest bracket mounting bolt (5) from transmission.
6. Remove the nuts from the front exhaust pipe/catalytic converter assembly to muffler flange.
7. Remove bolts (2) and flanged nuts (1) at the exhaust manifold.
8. Remove the front exhaust pipe/catalytic converter assembly (3) from the vehicle.
9. Remove steady rest bracket (4) from front exhaust pipe/catalytic converter assembly (3).
4.7L ENGINE
WARNING: If torches are used when working on the exhaust system, do not allow the flame near the fuel lines.
1. Raise and support the vehicle.
2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
3. Remove transmission crossmember (Refer to 13 - FRAME & BUMPERS/FRAME/REAR CROSSMEMBER - REMOVAL).
4. Disconnect and mark oxygen sensor electrical connectors.
5. Remove steady rest bracket mounting bolt (5) from transmission.
6. Remove the nuts from the front exhaust pipe/catalytic converter assembly to muffler flange.
7. Remove bolts (2) and flanged nuts (1) at the exhaust manifold.
8. Remove the front exhaust pipe/catalytic converter assembly (3) from the vehicle.
9. Remove steady rest bracket (4) from front exhaust pipe/catalytic converter assembly (3).
5.7L ENGINE
WARNING: If torches are used when working on the exhaust system, do not allow the flame near the fuel lines.
1. Raise and support the vehicle.
2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
3. Remove transmission crossmember (Refer to 13 - FRAME & BUMPERS/FRAME/REAR CROSSMEMBER - REMOVAL).
4. Disconnect and mark oxygen sensor electrical connectors.
5. Remove steady rest bracket mounting bolt (5) from transmission.
6. Remove the nuts from the front exhaust pipe/catalytic converter assembly to muffler flange.
7. Remove bolts (2) and flanged nuts (1) at the exhaust manifold.
8. Remove the front exhaust pipe/catalytic converter assembly (3) from the vehicle.
9. Remove steady rest bracket (4) from front exhaust pipe/catalytic converter assembly (3).
6.1L ENGINE
WARNING: If torches are used when working on the exhaust system, do not allow the flame near the fuel lines.
1. Raise and support the vehicle.
2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
3. Remove transmission crossmember (Refer to 13 - FRAME & BUMPERS/FRAME/REAR CROSSMEMBER - REMOVAL).
4. Disconnect and mark oxygen sensor electrical connectors.
5. Remove steady rest bracket mounting bolt (5) from transmission.
6. Remove the nuts from the front exhaust pipe/catalytic converter assembly to muffler flange.
7. Remove bolts (2) and flanged nuts (1) at the exhaust manifold.
8. Remove the front exhaust pipe/catalytic converter assembly (3) from the vehicle.
9. Remove steady rest bracket (4) from front exhaust pipe/catalytic converter assembly (3).
REMOVAL - DIESEL
WARNING: The normal operating temperature of the exhaust system is very high. therefore, never work around or attempt to service any part of the exhaust system until it is cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operation time.
1. Disconnect negative battery cable.
2. Raise vehicle on hoist.
3. Disconnect differential pressure ports (2).
4. Disconnect exhaust temperature sensors (3).
5. Disconnect downstream oxygen sensor connectors (4).
6. Remove exhaust from the diesel particulate filter (5).
7. Remove mounting bolts (4) and (7).
8. Remove the nuts from the down pipe (2).
9. Remove the catalyst assembly.
INSTALLATION - DIESEL
WARNING: The normal operating temperature of the exhaust system is very high. therefore, never work around or attempt to service any part of the exhaust system until it is cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operation time.
1. Install the catalyst assembly.
2. Install the nuts to the down pipe (2).
3. Install mounting bolts (4) and (7).
4. Install exhaust onto the diesel particulate filter (5).
5. Connect downstream oxygen sensor connectors (4).
6. Connect exhaust temperature sensors (3).
7. Connect differential pressure ports (2).
8. Connect negative battery cable.