Catalytic Converter Replacement Rear Wheel Drive

1. Raise the vehicle.
2. Support the vehicle with safety stands.
3. Support the catalytic converter assembly.



4. Remove the four oxygen sensor electrical connections and clips.



5. Remove the nuts from the muffler flange bolts.



6. Remove the nuts from the exhaust manifold studs (right side).
7. Remove the collars from the exhaust manifold studs (right side).



8. Remove the nuts from the exhaust manifold studs (left side).
9. Remove the collars from the exhaust manifold studs (left side).



10. Remove the catalytic converter assembly from the muffler assembly.
11. Remove the catalytic converter assembly from the exhaust manifolds.
12. Lower the front of the catalytic converter assembly.



13. Remove the catalytic converter assembly from the hanger.

Notice: Do not damage the oxygen sensors when removing the catalytic converter.

14. Remove the catalytic converter assembly from the vehicle by rotating the assembly over the rear of the transmission crossmember.

Notice: Do not damage the oxygen sensors when removing the catalytic converter.




1. Install the catalytic converter assembly to the hanger.



2. Install the collars on the catalytic converter assembly to the exhaust manifold studs (left side).
3. Loosely install the nuts onto the exhaust manifold studs (left side).



4. Install the collars on the catalytic converter assembly to the exhaust manifold studs (right side).
5. Loosely install the nuts onto the exhaust manifold studs (right side).



6. Install the catalytic converter assembly and the gasket to the muffler assembly.



7. Loosely install the nuts.

Tighten

•	Tighten the catalytic converter assembly-to-exhaust manifold nuts to 24 N·m (18 lb ft), in the proper sequence.

•	Tighten the catalytic converter assembly-to-muffler assembly nuts to 40 N·m (30 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




8. Install the four oxygen sensor electrical connections and clips.
9. Remove the support from the catalytic converter assembly.
10. Remove the safety stands from the vehicle.
11. Lower the vehicle from the hoist.

Catalytic Converter Replacement All Wheel Drive

1. Raise the vehicle.
2. Support the vehicle with safety stands.
3. Support the catalytic converter assembly.



4. Remove the four oxygen sensor electrical connections and clips.



5. Remove the nuts from the muffler flange bolts.



6. Remove the nuts from the exhaust manifold studs (right side).
7. Remove the collars from the exhaust manifold studs (right side).



8. Remove the nuts from the exhaust manifold studs (left hand).
9. Remove the collars from the exhaust manifold studs (left side).



10. Remove the catalytic converter assembly hanger from the transfer case adapter.
11. Remove the catalytic converter assembly hanger from the catalytic converter.
12. Separate the catalytic converter assembly from the muffler assembly.
13. Separate the catalytic converter assembly from the exhaust manifolds.

Notice: Do not damage the oxygen sensors when removing the catalytic converter.

14. Remove the catalytic converter assembly from the vehicle.
15. Lower the rear of the catalytic converter assembly.
16. Move the catalytic converter assembly toward the rear of the vehicle.
17. Rotate and lower the catalytic converter assembly behind the transfer case support crossmember.
18. Remove the catalytic converter assembly from the vehicle.

Notice: Do not damage the oxygen sensors when removing the catalytic converter.

1. Raise the catalytic converter assembly into the vehicle, from behind the transfer case support crossmember.
2. Rotate the catalytic converter assembly, while directing the left exhaust pipe between the torsion bar and the transmission.
3. Move the catalytic converter assembly toward the front of the vehicle.



4. Install the collars on the catalytic converter assembly to the exhaust manifold studs (left side). Loosely install the nuts onto the exhaust manifold studs (left side).



5. Install the collars on the catalytic converter assembly to the exhaust manifold studs (right side). Loosely install the nuts onto the exhaust manifold studs (right side).



6. Connect the catalytic converter assembly and gasket to the muffler assembly.
7. Loosely install the nuts.



8. Connect the catalytic converter assembly hanger to the catalytic converter assembly.
9. Connect the catalytic converter assembly hanger to the transfer case adapter.




Tighten

•	Tighten the catalytic converter assembly hanger-to-transfer case bolts to 52 N·m (38 lb ft).

•	Tighten the catalytic converter assembly-to-exhaust manifold nuts to 20 N·m (15 lb ft) in the proper sequence.

•	Tighten the catalytic converter assembly-to-muffler assembly nuts to 40 N·m (30 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




10. Install the four oxygen sensor electrical connections and the clips.
11. Remove the support from the catalytic converter assembly.
12. Remove the safety stands from the vehicle.
13. Lower the vehicle from the hoist.