Catalytic Converter: Service and Repair

Removal Procedure





Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

Notice: When jacking or lifting the vehicle from the frame side rails, be certain lift pads do not contact the three-way catalytic converter as damage to the converter will result.

Notice: Replacement of exhaust system parts must be OEM standard to ensure that the vehicle operates as designed.

1. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
2. Remove the transmission support. Refer to Transmission Support Replacement (RWD) or Transmission Support Replacement (4WD).
3. Disconnect the LH pre-converter Heated Oxygen Sensor (H02S) electrical connection.





4. Disconnect the RH pre-converter heated oxygen sensor (H02S) electrical connection.





5. Disconnect the post-converter heated oxygen sensor (H02S) electrical connection.





6. Remove the muffler to the catalytic converter flange nuts.
7. Remove the muffler from the catalytic converter.





8. Remove the catalytic converter to exhaust manifold flange nuts.





9. Remove the catalytic converter from the rubber catalytic converter hangers.
10. Remove the catalytic converter and gasket from the vehicle.
11. Remove the heated oxygen sensors (H02S) as necessary.

Installation Procedure





1. Install the Heated Oxygen Sensors (H02S) as necessary.
2. Install the catalytic converter and new gaskets to the vehicle.
3. Install the catalytic converter to the catalytic converter rubber hangers.





Notice: Refer to Fastener Notice in Service Precautions.

4. Install the catalytic converter to exhaust manifold flange nuts.

^ Tighten the catalytic converter to exhaust manifold nuts to 53 Nm (39 ft. lbs.).





5. Install the muffler and new gasket to the catalytic converter.
6. Install the muffler to the catalytic converter flange nuts.

^ Tighten the muffler to the catalytic converter flange nuts to 40 Nm (30 ft. lbs.).





7. Connect the post-converter heated oxygen sensor (H02S) electrical connection.





8. Connect the RH pre-converter heated oxygen sensor (H02S) electrical connection.





9. Connect the LH pre-converter heated oxygen sensor (H02S) electrical connection.
10. Install the transmission support. Refer to Transmission Support Replacement (RWD) or Transmission Support Replacement (4WD).
11. Lower the vehicle.