Catalytic Converter: Service and Repair

Catalytic Converter - 6.0L Diesel

Removal and Installation

WARNING: The normal operating temperature of the exhaust system is very high. Never attempt to service any part of the system until it has cooled. Be especially careful when working around the catalytic converter. The temperature of the catalytic converter rises to a high level after only a few minutes of engine operation. Failure to follow these instructions may result in personal injury.

CAUTION: Do not use oil- or grease-based lubricants on the isolators. These lubricants may cause deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger bracket during vehicle operation.

NOTE: Exhaust fasteners are of a prevailing torque design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Support the muffler and tailpipe assembly with a safety stand.
3. Release the front muffler and tailpipe and (if equipped, the extension pipe) hanger insulator(s).
4. Loosen the muffler and tailpipe or (if equipped, the extension pipe-to-catalytic converter Torca clamp nut) and release the tension on the clamp.
^ To install, tighten to 40 Nm (30 ft. lbs.).
5. Remove the muffler and tailpipe and (if equipped, the extension pipe) from the catalytic converter.
6. Release the catalytic converter hanger isolator.
7. Remove the 2 exhaust downpipe-to-catalytic converter nuts and discard.
^ To install, tighten to 40 Nm (30 ft. lbs.).
8. Remove the catalytic converter from the exhaust downpipe.
9. To install, reverse the removal procedure.