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

1. Lower the rear axle assembly. Refer to Rear Axle Replacement.
2. Remove the resonator pipe to the catalytic converter nuts.



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

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.

Caution: Refer to Fastener Caution in the Preface section.




5. Install the resonator pipe nuts.

Tighten
Tighten the resonator pipe nuts to 46 N·m (34 lb ft).

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

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

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

Note: 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.




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

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



3. Remove the insulators (1) from the muffler (3).
4. Using an appropriate tool, cut the resonator pipe (4) forward of the weld at the muffler inlet pipe.
5. Remove the muffler (3) from the vehicle.



6. Remove the resonator pipe nuts (3) from the catalytic converter (4).
7. Remove the resonator pipe (1) and the gasket (2) from the catalytic converter (4).
8. It may be necessary to deburr the resonator pipe and the muffler inlet pipe ends.

1. Install the new gasket (2) to the resonator pipe (1).
2. Install the resonator pipe (1) to the catalytic converter (4).

Caution: Refer to Fastener Caution in the Preface section.

3. Install the resonator pipe nuts (3).

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




4. Install the resonator pipe (2)  to the insulators (1).



5. Install the muffler (3) on to the resonator pipe (4).
6. Install the muffler (3)  on to the insulators (1).



7. Install the service clamp (1) on the exhaust muffler (2).
8. Install the service clamp nuts (3).

Tighten
Tighten the service clamp nuts to 45 N·m(33 lb ft).

9. Remove the support from the exhaust system.
10. Inspect for exhaust leaks and underbody clearance.