Exhaust Manifold Pipe Replacement

Exhaust Manifold Pipe Replacement

Removal Procedure




1. Remove the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis) (Service and Repair)Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) (Service and Repair)Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) (Service and Repair).
2. Support the transmission with a suitable transmission jack.
3. Remove the transmission mount to transmission support nuts.
4. Using the transmission jack, raise the transmission up off of the transmission support.




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




7. Remove the exhaust muffler to exhaust manifold pipe nuts (1).




8. Remove the exhaust manifold pipe to exhaust manifold nuts.
9. Using the transmission jack, lower the transmission slightly.
10. Separate any necessary exhaust muffler insulators so that the pipe may be separated from the muffler.




11. Remove the exhaust manifold pipe.
12. Discard the exhaust manifold pipe gasket.

Installation Procedure




1. Install a NEW exhaust manifold pipe gasket onto the muffler studs.
2. Install the exhaust manifold pipe.




3. Install any necessary exhaust muffler insulators that were separated from the muffler.
4. Using the transmission jack, raise the transmission slightly.

Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the exhaust manifold pipe to exhaust manifold nuts and tighten to 50 Nm (37 lb ft).




6. Install the exhaust muffler to exhaust manifold pipe nuts (1) and tighten to 45 Nm (33 lb ft).




7. Position the transmission support crossmember.
8. Install the transmission support crossmember bolts and tighten to 95 Nm (70 lb ft).




9. Using the transmission jack, lower the transmission onto the transmission support.
10. Install the transmission mount to transmission support nuts and tighten to 40 Nm (30 lb ft).
11. Remove the support from the transmission.
12. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis) (Service and Repair)Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) (Service and Repair)Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) (Service and Repair).