Catalytic Converter: Service and Repair

Catalytic Converter Replacement (6.6L Engine)

Removal Procedure





1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Support the transmission with a suitable transmission jack.
3. Remove the transmission mount to transmission support nuts.
4. Raise the transmission off of the transmission support.





5. Remove the transmission support crossmember bolts.
6. Remove the transmission support crossmember.





7. Loosen the catalytic converter coupling nuts (1).





8. Loosen the exhaust pipe clamp.
9. Slide the exhaust pipe clamp up onto the exhaust pipe.
10. Slide the catalytic converter hanger out of the insulator.





11. Gently pry up the catalytic converter coupling clip (1) (on the muffler end) in order to disengage the locator button (3) from the coupling clip.
12. Remove the catalytic converter.
13. Gently pry up the catalytic converter coupling clip (1) (on the catalytic converter end).
14. Slide the catalytic converter coupling off the catalytic converter.

Installation Procedure





1. Align the catalytic converter coupling groove to the catalytic converter locator button.
2. Install the catalytic converter coupling until the catalytic converter locator button is fully engaged by the coupling clip.
3. Position the catalytic converter.
4. Align the catalytic converter coupling groove (2) to the muffler locator button (3).
5. Install the catalytic converter until the muffler locator button is fully engaged by the coupling clip (1).





6. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation.
7. Slide the catalytic converter hanger into the insulator.
8. Slide the exhaust pipe clamp down.

9. Notice: Refer to Fastener Notice in Service Precautions.

Tighten the exhaust pipe clamp.
Tighten the clamp to 15 Nm (11 ft. lbs.).





10. Tighten both catalytic converter coupling nuts (1) until snug.
11. Once snug, tighten the catalytic converter coupling nuts to specifications.
Tighten the nuts to 45 Nm (33 ft. lbs.).





12. Install the transmission support crossmember.
13. Install the transmission support crossmember bolts.
Tighten the bolts to 95 Nm (70 ft. lbs.).





14. Lower the transmission onto the transmission support.
15. Install the transmission mount to transmission support nuts.
Tighten the bolts to 40 Nm (30 ft. lbs.).
16. Remove the support from the transmission.
17. Lower the vehicle.