Technical Procedure
1. Install seat and fender covers and raise the vehicle on a hoist.Inspection: The converter need not be replaced -
^ If it is one of the new type basketed converter assemblies, part number 25056622.
^ If it is one of the converters used in Dealer Technical Bulletin
82-T-27, part number 25056894.
FIGURE 1:
The part numbers are stamped on the bottom of the inboard flange near the converter inlet. Refer to Figure 1.
Proceed to Step 15 if replacement of the converter is not required.
2. If the converter is of the original type, remove both converter clamps and brackets.
3. Remove the A.I.R. clamp and pipe.
4. Remove the converter (using a torch to heat the joints.)
CAUTION: The catalytic converter beads contain platinum, palladium, and/or rhodium. Additionally, the beads may be finely coated with lead compounds. Therefore, precautions should be taken to minimize dust generation during the replacement procedure. These pre-cautions include:
A. Catalyst dust should be controlled by wetting with water prior to bead removal, as described in Step 5.
B. The use of a suitable dust mask, rubber gloves, and safety glasses is recommended when handling catalyst beads.
C. Applicable OSHA standards should be reviewed.
D. Allow converter to cool before handling.
5. Stand the old converter upright on the inlet end and pour 16 ounces of water into the outlet to control catalyst dust.
FIGURE 1:
FIGURE 2:
6. Using a hammer and chisel, remove the fill hole plug from the lower bed. (The smooth side of the converter is the lower bed side). See Figure 1 and 2.
7. Hold the converter over a clean pan (J-34155-2) and empty the catalyst beads by shaking. It may be necessary to tap the converter belt flange with a hammer to loosen the beads.
8. Pour the beads into a sifting pan (J-34155-1) and sift to remove under-sized beads.
9. Prop the new converter up at a 45-degree angle with the lower bed fill hole at the top.
10.. Using funnel J-34155-3, pour the sifted beads into the lower bed of the new converter. If additional beads are required to completely fill the lower bed, it will be necessary to obtain a lower bed bead kit from the parts department. Excess beads from the kit should be saved in a clean container for future use.
FIGURE 2:
11. Lay the converter down on a flat surface with the lower bed fill hole on top. Figure 2.
12. Insert the fill plug into the lower bed fill hole. The fill plug outer rim must rest against the converter body.
FIGURE 3:
13. Insert the plug installer tool (J-34118) into the fill plug and tighten to a torque of 47 N-m (35 ft.lbs.). Figure 3.
14. Install the converter on the vehicle by reversing the removal procedure.
CAMPAIGN IDENTIFICATION LABEL:
15. Install a Campaign Identification label. Each vehicle modified in accordance with the instructions outlined in this Service Procedure will require a Campaign Identification label. Each label provides a space to include the campaign number, the five (5) digit dealer code of the dealer performing the campaign service, and the date vehicle was campaigned. This information may be inserted with a typewriter or ballpoint pen. When installing label, clean the surface of the radiator upper mounting support and apply the campaign label where it is readily visible.