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For 1990-2009 cars only

Exhaust Muffler with Resonator, Exhaust, and Tail Pipe Replacement LNF

Removal Procedure


    Object Number: 1631765  Size: SH
  1. Lower the rear axle assembly. Refer to Rear Axle Replacement .
  2. Remove the resonator pipe to the catalytic converter nuts .

  3. Object Number: 1631769  Size: SH
  4. Separate the resonator pipe and the muffler from the insulators.
  5. With the aid of an assistant, remove the resonator pipe and the muffler as one unit from the vehicle.
  6. Discard the catalytic converter to the resonator pipe gasket.

Installation Procedure


    Object Number: 1631769  Size: SH
  1. To aid in installation, add a non petroleum based lubricant onto the insulators.
  2. Clean the mating surface on the catalytic converter of any remaining gasket material.
  3. With the aid of an assistant, install the resonator pipe and the muffler to the insulators.
  4. Position the new gasket on to the resonator pipe and install the resonator pipe to the catalytic converter.
  5. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1631765  Size: SH
  6. Install the resonator pipe nuts.
  7. Tighten
    Tighten the resonator pipe nuts to 46 N·m (34 lb ft).

  8. Install the rear axle assembly. Refer to Rear Axle Replacement .
  9. Inspect for exhaust leaks and underbody clearance.

Exhaust Muffler with Resonator, Exhaust, and Tail Pipe Replacement L61, LE5

Removal Procedure

    Notice: Do not over-flex or damage the flex joint when moving the flex joint from the normal mounting position.

    Important: A service muffler will be needed when replacing the exhaust resonator pipe on a factory equipped exhaust system.

  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

  2. Object Number: 2035152  Size: SH

    Important: Using an appropriate jack stand, support the exhaust resonator pipe.

  3. Remove the insulators (1) from the resonator pipe (2).

  4. Object Number: 2040443  Size: SH
  5. Remove the insulators (1) from the muffler (3).
  6. Using an appropriate tool, cut the resonator pipe (4) forward of the weld at the muffler inlet pipe.
  7. Remove the muffler (3) from the vehicle.

  8. Object Number: 2035153  Size: SH
  9. Remove the resonator pipe nuts (3) from the catalytic converter (4).
  10. Remove the resonator pipe (1) and the gasket (2) from the catalytic converter (4).
  11. It may be necessary to deburr the resonator pipe and the muffler inlet pipe ends.

Installation Procedure


    Object Number: 2035153  Size: SH
  1. Install the new gasket (2) to the resonator pipe (1).
  2. Install the resonator pipe (1) to the catalytic converter (4).
  3. Notice: Refer to Fastener Notice in the Preface section.

  4. Install the resonator pipe nuts (3).
  5. Tighten
    Tighten the resonator pipe nuts to 30 N·m (22 lb ft).


    Object Number: 2035152  Size: SH
  6. Install the resonator pipe (2)  to the insulators (1).

  7. Object Number: 2040443  Size: SH
  8. Install the muffler (3) on to the resonator pipe (4).
  9. Install the muffler (3)  on to the insulators (1).

  10. Object Number: 2035079  Size: MH
  11. Install the service clamp (1) on the exhaust muffler (2).
  12. Install the service clamp nuts (3).
  13. Tighten
    Tighten the service clamp nuts to 45 N·m(33 lb ft).

  14. Remove the support from the exhaust system.
  15. Inspect for exhaust leaks and underbody clearance.