GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2007 🢒 TopKick C-Series (Conventional) C4/C5 🢒 Engine 🢒 Engine Exhaust 🢒 Exhaust Muffler Replacement

Removal Procedure
  1. If equipped with welded exhaust, the complete Exhaust System must be replaced.

    2. Object Number: 738368 Size: SH
  2. Remove the nuts from the catalytic converter to muffler flange (gasoline engines).

    3. Object Number: 213188 Size: SH
  3. Remove the clamp assemblies to and from the muffler as used.

    4. Object Number: 206339 Size: SH
  4. Remove the clamp assemblies that are around the muffler as used.
  5. Remove the nuts.
  6. Remove the muffler.
  7. Inspect all of the components for the following conditions:
    8. • Cracks
    • Bends
    • Stripped threads
    • Corrosion damage
    • Leaks
  8. Replace the above components, as necessary.

Installation Procedure

    Object Number: 213188 Size: SH
  1. Slide the clamp assemblies over the muffler ends.
  2. Install the exhaust clamps around the muffler.
  3. Install a new tail pipe whenever you replace the muffler.

    4. Object Number: 738368 Size: SH

    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.

  4. Install the nuts to the catalytic converter to muffler flange.

    5. Tighten
    Tighten the nuts to 64 N·m (47 lb ft).


    Object Number: 206339 Size: SH
  5. Install the nuts and the bolts.

    6. Tighten

    1. Tighten the exhaust hanger nuts to 29 N·m (21 lb ft).
    2. Tighten the muffler clamp nuts on gasoline engines to 60 N·m (44 lb ft).
    3. Tighten the muffler clamp bolts on diesel engines to 73 N·m (54 lb ft).