For 1990-2009 cars only
Exhaust Muffler Replacement 1500 - LMG/LY2/LY5
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
- Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
- Disconnect the chassis wiring harness electrical connector (1) from the right rear wheel speed sensor wiring harness electrical connector (2).
- If the vehicle is equipped with regular production option (RPO) Z55, disconnect the chassis wiring harness electrical connector (3) from the right rear shock absorber.
- If the vehicle is equipped with RPO Z55, disconnect the right rear air line from the shock absorber.
- Remove the right rear wheel speed sensor wiring harness electrical connector clip from the frame.
- Remove the right rear wheel speed sensor wiring harness clips from the frame and the control arm bracket.
- Disconnect the right rear automatic level control sensor link rod from the sensor. Perform the following:
- Install a suitable adjustable jack under the rear axle.
- Remove the right axle tie rod bolt (2) and nut (1).
- Remove the rear axle vent hose from the rear axle, if necessary.
- Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary.
- Remove the right rear stabilizer shaft link to frame bolt and nut.
- Remove the right rear stabilizer shaft link from the frame.
- Remove the right rear shock absorber lower bolt and nut.
- Lower the right side of the rear axle using the adjustable jack in order to remove the muffler.
- Remove the catalytic converter to muffler nuts.
- Lubricate the insulators where the muffler assembly hangers are inserted in order to ease in removal.
- With the aid of an assistant, remove the insulators from the exhaust system hangers (2 and 3).
- With the aid of an assistant, remove the insulator from the exhaust system hanger near the resonator.
- Remove the muffler assembly.
Important: The rear axle wiring harness clip is a one way clip with a D-shape section. The clip can only be installed and/or removed in only one direction.
Important: Do not attempt to pry the rear suspension sensor link rod from the rear position sensor ball stud.
| 7.1. | Support the sensor lever with your hand. |
| 7.2. | Twist the link rod ball in order to separate it from the ball stud. |
Important: During removal, do not over extend the flex coupler as internal damage may occur.
Installation Procedure
- Lubricate the insulators where the muffler assembly hangers are inserted for ease of installation.
- With the aid of an assistant, install the muffler assembly.
- With the aid of an assistant, install the insulators to the exhaust system hangers (2 and 3).
- Install the insulator to the exhaust system hanger near the resonator.
- Install the catalytic converter to muffler nuts.
- Raise the right side of the rear axle into position using the adjustable jack.
- Install the right rear shock absorber lower bolt and nut.
- Install the right rear stabilizer shaft link to the frame.
- Install the right rear stabilizer shaft link to frame bolt and nut.
- Install the right rear axle tie rod bolt (2) and nut (1).
- Install the rear axle vent hose to the rear axle, if necessary.
- Install the vent hose swivel clip to the rear brake crossover pipe, if necessary.
- Using the J 38185 install the right rear link rod to the ball studs on the sensors.
- Install the right rear wheel speed sensor wiring harness clips to the frame and the control arm bracket.
- Install the right rear wheel speed sensor wiring harness electrical connector clip to the frame.
- If the vehicle is equipped with RPO Z55, connect the right rear air line to the shock absorber.
- If the vehicle is equipped with RPO Z55, connect the chassis wiring harness electrical connector (3) to the right rear shock absorber.
- Connect the chassis wiring harness electrical connector (1) to the right rear wheel speed sensor wiring harness electrical connector (2).
- Lower the vehicle.
Notice: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.
Notice: Refer to Fastener Notice in the Preface section.
Tighten
Tighten the nuts to 45 N·m (33 lb ft).
Tighten
Tighten the bolt/nut to 95 N·m (70 lb ft).
Tighten
Tighten the bolt/nut to 65 N·m (48 lb ft).
Tighten
Tighten the bolt/nut to 105 N·m (77 lb ft).
Important: The rear axle wiring harness clip is a one way clip with a D-shape section. The clip can only be installed and/or removed in only one direction.
Exhaust Muffler Replacement 1500 - L92
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
- Remove the right rear wheel and tire. Refer to Tire and Wheel Removal and Installation .
- Disconnect the chassis wiring harness electrical connector (1) from the right rear wheel speed sensor wiring harness electrical connector (2).
- If the vehicle is equipped with regular production option (RPO) Z55, disconnect the chassis wiring harness electrical connector (3) from the right rear shock absorber.
- If the vehicle is equipped with RPO Z55, disconnect the right rear air line from the shock absorber.
- Remove the right rear wheel speed sensor wiring harness electrical connector clip from the frame.
- Remove the right rear wheel speed sensor wiring harness clips from the frame and the control arm bracket.
- Disconnect the right rear automatic level control sensor link rod from the sensor. Perform the following:
- Install a suitable adjustable jack under the rear axle.
- Remove the right axle tie rod bolt (2) and nut (1).
- Remove the rear axle vent hose from the rear axle, if necessary.
- Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary.
- Remove the right rear stabilizer shaft link to frame bolt and nut.
- Remove the right rear stabilizer shaft link from the frame.
- Remove the right rear shock absorber lower bolt (4) and nut (3).
- Lower the right side of the rear axle using the adjustable jack in order to remove the muffler.
- Remove the muffler to catalytic converter nuts.
- Separate the hanger.
- If the vehicle is a Yukon Denali or Escalade perform the following steps, otherwise proceed to step 26.
- Lubricate the insulators where the muffler assembly hangers are inserted in order to ease in removal.
- With the aid of an assistant, remove the insulators from the exhaust system hangers (4, and 5).
- With the aid of an assistant, remove the insulator from the exhaust system hanger near the resonator.
- Remove the muffler assembly.
- If the vehicle is a Yukon XL, Yukon Denali XL, Escalade ESV, or Escalade EXT perform the following steps.
- Lubricate the insulators where the muffler assembly hangers are inserted in order to ease in removal.
- With the aid of an assistant, remove the insulators from the exhaust system hangers (3, 4, and 5).
- With the aid of an assistant, remove the insulator from the exhaust system hanger near the resonator.
- Remove the muffler assembly.
Important: The rear axle wiring harness clip is a one way clip with a D-shape section. The clip can only be installed and/or removed in only one direction.
Important: Do not attempt to pry the rear suspension sensor link rod from the rear position sensor ball stud.
| 7.1. | Support the sensor lever with your hand. |
| 7.2. | Twist the link rod ball in order to separate it from the ball stud. |
Important: During removal, do not over extend the flex coupler as internal damage may occur.
Installation Procedure
- If the vehicle is a Yukon XL, Yukon Denali XL, Escalade ESV, or Escalade EXT perform the following steps, otherwise proceed to step 6.
- Lubricate the insulators where the muffler assembly hangers are inserted for ease of installation.
- With the aid of an assistant, install the muffler assembly.
- With the aid of an assistant, install the insulators to the exhaust system hangers (3, 4, and 5).
- With the aid of an assistant, Install the insulator to the exhaust system hanger near the resonator.
- If the vehicle is a Yukon Denali or Escalade perform the following.
- Lubricate the insulators where the muffler assembly hangers are inserted for ease of installation.
- With the aid of an assistant, install the muffler assembly.
- With the aid of an assistant, install the insulators to the exhaust system hangers (2, and 3).
- Install the insulator to the exhaust system hanger near the resonator.
- Install the muffler to catalytic converter nuts.
- Install the insulator to the hanger.
- Raise the rear axle into position using the adjustable jack.
- Install the right rear shock absorber lower bolt and nut.
- Install the right rear stabilizer shaft link to the frame.
- Install the right rear stabilizer shaft link to frame bolt and nut.
- Install the right rear axle tie rod bolt (2) and nut (1).
- Install the rear axle vent hose to the rear axle, if necessary.
- Install the vent hose swivel clip to the rear brake crossover pipe, if necessary.
- Using the J 38185 install the right rear link rod to the ball studs on the sensors.
- Install the right rear wheel speed sensor wiring harness clips to the frame and the control arm bracket.
- Install the right rear wheel speed sensor wiring harness electrical connector clip to the frame.
- If the vehicle is equipped with RPO Z55, connect the right rear air line to the shock absorber.
- If the vehicle is equipped with RPO Z55, connect the chassis wiring harness electrical connector (3) to the right rear shock absorber.
- Connect the chassis wiring harness electrical connector (1) to the right rear wheel speed sensor wiring harness electrical connector (2).
- Install the right rear wheel and tire. Refer to Tire and Wheel Removal and Installation .
Important: During installation, do not over extend the flex coupler as internal damage may occur.
Notice: Refer to Fastener Notice in the Preface section.
Tighten
Tighten the nuts to 45 N·m (33 lb ft).
Tighten
Tighten the bolt/nut to 95 N·m (70 lb ft).
Tighten
Tighten the bolt/nut to 65 N·m (48 lb ft).
Tighten
Tighten the bolt/nut to 105 N·m (77 lb ft).
Important: The rear axle wiring harness clip (1) is a one way clip with a D-shape section. The clip can only be installed and/or removed in only one direction.
Exhaust Muffler Replacement 2500
Removal Procedure
- Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
- Remove the exhaust muffler to right catalytic converter nuts.
- Loosen the exhaust pipe clamp at the left catalytic converter.
- Lubricate the insulators where the muffler assembly hangers are inserted in order to ease in removal.
- With the aid of an assistant, remove the insulators from the exhaust system hangers (4, 5, and 6).
- Pull the muffler assembly rearward in order to separate the muffler from the catalytic converters. Once the muffler is separated from the converters, move and rotate the muffler towards the front of the vehicle, removing the muffler from the vehicle.
Installation Procedure
- Lubricate the insulators where the muffler assembly hangers are inserted in order to ease installation.
- With the aid of an assistant, install the muffler assembly. Rotate the muffler into position over the rear axle, move the muffler rearward, then forward installing the muffler to the catalytic converters.
- Install the insulators to the exhaust system hangers (4, 5, and 6).
- Tighten the exhaust pipe clamp at the left catalytic converter.
- Install the exhaust muffler to right catalytic converter nuts.
- Lower the vehicle.
Notice: Refer to Fastener Notice in the Preface section.
Tighten
Tighten the clamp to 44 N·m (32 lb ft).
Tighten
Tighten the nuts to 45 N·m (33 lb ft).
Exhaust Muffler Replacement 1500 - LC9/LMG/LY5/L76
Tools Required
J 38185 Hose Clamp Pliers
Removal Procedure
- Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
- Disconnect the chassis wiring harness electrical connector (1) from the right rear wheel speed sensor wiring harness electrical connector (2).
- If the vehicle is equipped with regular production option (RPO) Z55, disconnect the chassis wiring harness electrical connector (3) from the right rear shock absorber.
- If the vehicle is equipped with RPO Z55, disconnect the right rear air line from the shock absorber.
- Remove the right rear wheel speed sensor wiring harness electrical connector clip from the frame.
- Remove the right rear wheel speed sensor wiring harness clips from the frame and the control arm bracket.
- Disconnect the right rear automatic level control sensor link rod from the sensor. Perform the following:
- Install a suitable adjustable jack under the rear axle.
- Remove the right axle tie rod bolt (2) and nut (1).
- Remove the rear axle vent hose from the rear axle, if necessary.
- Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary.
- Remove the right rear stabilizer shaft link to frame bolt and nut.
- Remove the right rear stabilizer shaft link from the frame.
- Remove the right rear shock absorber lower bolt (4) and nut (3).
- Lower the right side of the rear axle using the adjustable jack in order to remove the muffler.
- Remove the catalytic converter to muffler nuts.
- Lubricate the insulators where the muffler assembly hangers are inserted in order to ease in removal.
- With the aid of an assistant, remove the insulators from the exhaust system hangers (1, 2, and 3).
- With the aid of an assistant, remove the insulator from the exhaust system hanger near the resonator.
- Remove the muffler assembly.
Important: The rear axle wiring harness clip is a one way clip with a D-shape section. The clip can only be installed and/or removed in only one direction.
Important: Do not attempt to pry the rear suspension sensor link rod from the rear position sensor ball stud.
| 7.1. | Support the sensor lever with your hand. |
| 7.2. | Twist the link rod ball in order to separate it from the ball stud. |
Important: During removal, do not over extend the flex coupler as internal damage may occur.
Installation Procedure
- Lubricate the insulators where the muffler assembly hangers are inserted for ease of installation.
- With the aid of an assistant, install the muffler assembly.
- With the aid of an assistant, install the insulators to the exhaust system hangers (1, 2, and 3).
- Install the insulator to the exhaust system hanger near the resonator.
- Install the catalytic converter to muffler nuts.
- Raise the rear axle into position using the adjustable jack.
- Install the right rear shock absorber lower bolt and nut.
- Install the right rear stabilizer shaft link to the frame.
- Install the right rear stabilizer shaft link to frame bolt and nut.
- Install the right rear axle tie rod bolt (2) and nut (1).
- Install the rear axle vent hose to the rear axle, if necessary.
- Install the vent hose swivel clip to the rear brake crossover pipe, if necessary.
- Using the J 38185 install the right rear link rod to the ball studs on the sensors.
- Install the right rear wheel speed sensor wiring harness clips to the frame and the control arm bracket.
- Install the right rear wheel speed sensor wiring harness electrical connector clip to the frame.
- If the vehicle is equipped with RPO Z55, connect the right rear air line to the shock absorber.
- If the vehicle is equipped with RPO Z55, connect the chassis wiring harness electrical connector (3) to the right rear shock absorber.
- Connect the chassis wiring harness electrical connector (1) to the right rear wheel speed sensor wiring harness electrical connector (2).
- Lower the vehicle.
Important: During installation, do not over extend the flex coupler as internal damage may occur.
Notice: Refer to Fastener Notice in the Preface section.
Tighten
Tighten the nuts to 45 N·m (33 lb ft).
Tighten
Tighten the bolt/nut to 95 N·m (70 lb ft).
Tighten
Tighten the bolt/nut to 65 N·m (48 lb ft).
Tighten
Tighten the bolt/nut to 105 N·m (77 lb ft).
Important: The rear axle wiring harness clip is a one way clip with a D-shape section. The clip can only be installed and/or removed in only one direction.
