Catalytic Converter Replacement Single Exhaust - 4.3L, 4.8L and 5.3L

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Disconnect the heated oxygen sensor (HO2S) electrical connections from catalytic converter pipe.
3. Remove the exhaust hanger bolts and hanger from the transmission.
4. Remove the nuts and the seals retaining the catalytic converter pipe to the exhaust manifolds.




Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

5. Remove the flange nuts from the catalytic pipe to the muffler.
6. Remove the catalytic converter from the vehicle.
7. Remove the oxygen sensors as necessary. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 .

1. Install the oxygen sensors as necessary. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 .
2. Position the catalytic pipe to the vehicle.
3. Install the retaining nuts to the front of the muffler.

Do not tighten the nuts.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the new seals, the nuts and the exhaust pipe flange to exhaust manifold.

Tighten

•	Tighten the exhaust pipe flange to exhaust manifold nuts to 65 N·m (48 lb ft).

•	Tighten the catalytic converter to muffler retaining nuts to 48 N·m (35 lb ft).




5. Connect the HO2S electrical connections.
6. Install the exhaust hanger and bolts to the transmission.

Tighten
Tighten the bolts to 17 N·m (13 lb ft).

Notice: When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment insulation and trim materials.

7. Verify the exhaust system for proper clearance and the alignment of all components.
8. Lower the vehicle.

Catalytic Converter Replacement 6.0L - Right

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Disconnect the oxygen sensor connectors.
3. Remove the exhaust hanger bolts and hanger from the vehicle.

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

4. Remove the nuts retaining the exhaust pipe flange to the catalytic converter pipe.
5. Loosen the nut retaining the exhaust pipe clamp to the muffler.
6. Remove the exhaust pipe and flange gasket.

Notice: Refer to Fastener Notice in the Preface section.

1. Remove the oxygen sensors and install into new exhaust pipe.

Tighten
Tighten the sensors to 42 N·m (31 lb ft).




2. Install new gasket to the catalytic converter pipe flange.
3. Install the exhaust pipe to the vehicle.
4. Install the nuts for the catalytic converter pipe to exhaust pipe.

Tighten
Tighten the flange nuts to 48 N·m (35 lb ft).

5. Tighten the exhaust pipe clamp nut.

Tighten
Tighten the nut to 54 N·m (40 lb ft).

Notice: When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment insulation and trim materials.

6. Verify the exhaust system for proper clearance and the alignment of all components.
7. Install the exhaust hanger and bolts.

Tighten
Tighten the bolts to 17 N·m (13 lb ft).

8. Lower the vehicle.

Catalytic Converter Replacement 6.0L - Left

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Disconnect the oxygen sensors.
3. Remove the exhaust hanger bolts and hanger from the vehicle.

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

4. Remove the nuts retaining the exhaust pipe flange to the catalytic converter pipe.
5. Remove the nuts retaining the exhaust pipe flange to the muffler.
6. Remove the exhaust pipe.
7. Remove the flange gasket.

Notice: Refer to Fastener Notice in the Preface section.

1. Remove the oxygen sensors and install into the new exhaust pipe.

Tighten
Tighten the sensors to 42 N·m (31 lb ft).




2. Install new gaskets to the muffler flange and the catalytic converter pipe flange.
3. Install the exhaust pipe.
4. Install the nuts for the catalytic converter pipe to the exhaust pipe.

Tighten
Tighten the flange nuts to 48 N·m (35 lb ft).

5. Install the nuts for the muffler to the exhaust pipe.

Tighten
Tighten the nuts to 48 N·m (35 lb ft).

6. Connect the oxygen sensor connectors.
7. Install the exhaust hanger and bolts.

Tighten
Tighten the bolts to 17 N·m (13 lb ft).

Notice: When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment insulation and trim materials.

8. Verify the exhaust system for proper clearance and the alignment of all components.
9. Lower the vehicle.

Catalytic Converter Replacement 6.6L

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Support the transmission with a suitable transmission jack.
3. Remove the transmission mount to transmission support nuts.
4. Raise the transmission off of the transmission support.



5. Remove the transmission support crossmember bolts.
6. Remove the transmission support crossmember.



7. Remove the exhaust muffler nuts.



8. Loosen the exhaust pipe clamp.
9. Slide the exhaust pipe clamp up onto the exhaust pipe adapter.



10. Slide the catalytic converter hanger out of the exhaust pipe hanger bracket and remove the catalytic converter.

1. Install the catalytic converter.
2. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation.
3. Slide the catalytic converter hanger into the exhaust pipe hanger bracket.



4. Install the exhaust muffler nuts until snug.




Important: Ensure that the manifold pipe is square to the exhaust pipe adapter.

5. Slide the exhaust pipe clamp down and around the pipe connection.

Notice: Refer to Fastener Notice in the Preface section.

6. Tighten the exhaust pipe clamp and muffler nuts.

Tighten

•	Tighten the clamp to 40 N·m (30 lb ft).

•	Tighten the nuts to 40 N·m (30 lb ft).




7. Lower the transmission onto the transmission support.
8. Install the transmission mount to transmission support nuts.

Tighten
Tighten the bolts to 40 N·m (30 lb ft).

9. Remove the support from the transmission.
10. Lower the vehicle.