Catalytic Converter Replacement Gas, Below8600 lb (GVWR)

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



2. Disconnect the oxygen sensor electrical connections.



3. Remove the nuts from the Y-pipe flat flange.



4. Remove the nuts, the studs and the flange seals from the Y-pipe and the exhaust manifold.
5. Remove the Y-pipe and the catalytic converter assembly.

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.

1. Install the new flange seals to the connecting the Y-pipe, catalytic converter assembly at the exhaust manifold.
2. Install the studs into the exhaust manifold.

Tighten
Tighten the studs to 22 N·m (16 lb ft).

3. Install the nuts to the studs in the exhaust manifold.

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




4. Position the Y-pipe and the catalytic converter assembly to the flat flange.



5. Install the nuts to the flat flange studs.

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




6. Connect the oxygen sensor electrical connections.
7. Check for clearance and alignment.
8. Lower the vehicle.

Catalytic Converter Replacement Diesel

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



2. Remove the front exhaust pipe flange stud nuts from the front of the catalytic converter assembly.

Remove the clamp from the exhaust manifold pipe.




3. Remove the U-bolt from the rear of the catalytic converter assembly.



4. Remove the catalytic converter from the muffler assembly.

1. Install a new flange gasket and the catalytic converter to the front exhaust pipe flange studs.




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.

2. Install the nuts to the exhaust pipe flange studs.

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




3. Install a new U-bolt to the rear of the catalytic converter.

Tighten
Tighten the U-bolt to 42 N·m (31 lb ft).

4. Install the clamp to the exhaust manifold pipe.

Tighten
Tighten the clamp nuts to 12 N·m ( 106 lb in).

5. Check for clearance and alignment.
6. Lower the vehicle.

Catalytic Converter Replacement Gas, Export

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



2. Remove the nuts from the Y-pipe flat flange.
3. Remove the muffler and the catalytic converter assembly.



4. Remove the nuts, studs, and flange seals from the Y-pipe and the exhaust manifold.

1. Install the new flange seals.

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.

2. Install the new studs.

Tighten
Tighten the studs to 22 N·m (16 lb ft).

3. Install the new nuts connecting the Y-pipe, catalytic converter assembly to the exhaust manifold.

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




4. Position the Y-pipe and the catalytic converter assembly to the flat flange.
5. Install the nuts to the flat flange studs.

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

6. Check for clearance and alignment.
7. Lower the vehicle.

Catalytic Converter Replacement Gas, 8600 lb and Above

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



2. Disconnect the oxygen sensor electrical connections.



3. Remove the nuts from the Y-pipe flat flange.



4. Remove the nuts, studs and flange seals from the Y-pipe and the exhaust manifold.



5. Remove the Y-pipe and the catalytic converter assembly.
6. Remove the muffler and the catalytic converter assembly.

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.

1. Install the flange seals to the Y-pipe, catalytic converter assembly at the exhaust manifold.
2. Install the studs into the exhaust manifold.

Tighten
Tighten the studs to 22 N·m (16 lb ft).

3. Install the exhaust nuts to the studs in the exhaust manifold.

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

4. Install the muffler and the catalytic converter assembly.



5. Position the Y-pipe and the catalytic converter assembly to the flat flange.
6. Install the nuts to the flat flange studs.

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




7. Connect the oxygen sensor electrical connections.
8. Check for clearance and alignment.
9. Lower the vehicle.