GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 HUMMER 🢒 2005 🢒 H2 🢒 General Information 🢒 General Information 🢒 Exhaust Muffler Replacement

Removal Procedure
  1. Deflate the rear suspension air bags, if equipped. Refer to Air Suspension Depressurization .
  2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .

    3. Object Number: 665520 Size: SH
  3. Remove the exhaust muffler to catalytic converter flange nuts.
  4. Loosen the exhaust pipe clamp.
  5. Support the rear axle with jack stands.
  6. Remove the right side lower stabilizer nut and position link aside.
  7. Remove the rear track bar right hand nut and bolt.
  8. Remove the right hand rear shock lower bolt and nut.
  9. Disconnect the right hand air suspension level sensor, if equipped. Refer to Air Spring Leveling Sensor Replacement .
  10. Lower the axle.

    11. Object Number: 863025 Size: SH
  11. Remove the insulators from the frame hangers.
  12. With the aid of an assistant, slide the muffler rearward in order to remove the muffler from the catalytic converter.
  13. Remove the insulators from the muffler hangers.
  14. Remove the muffler from the vehicle.

Installation Procedure

    Object Number: 863025 Size: SH

    Important: Apply lubricant to the insulators to aid in installation.

  1. Install the insulators to the muffler hangers.
  2. With the aid of an assistant, slide the muffler forward in order to install the muffler to the catalytic converter.
  3. Install the insulators to the frame hangers.

    4. Object Number: 665520 Size: SH
  4. Install the exhaust muffler nuts, until snug.

    5. Notice: Refer to Fastener Notice in the Preface section.

  5. Tighten the exhaust pipe clamp bolt and muffler nuts.

    6. Tighten

        • Tighten the exhaust muffler nuts to 40 N·m (30 lb ft).
        • Tighten the exhaust pipe clamp to 44 N·m (33 lb ft).
  6. Raise the rear suspension to ride height.
  7. Connect the right hand air suspension level sensor, if equipped. Refer to Air Spring Leveling Sensor Replacement .
  8. Install the right hand shock lower bolt and nut.

    9. Tighten
    Tighten the bolt and nut to 105 N·m (77 lb ft)

  9. Install the rear track bar bolt and nut.

    10. Tighten
    Tighten the bolt and nut to 105 N·m (77 lb ft)

  10. Install the right hand lower stabilizer nut.

    11. Tighten
    Tighten the nut to 72 N·m (53 lb ft)

  11. Remove the jack stands from under the rear axle.
  12. Lower the vehicle. Ensure the air springs seat properly as the vehicle is being lowered.
  13. If equipped with air suspension, start the engine and idle for 2 minutes to ensure the air spring leveling system is functioning properly.