Service Procedure For 1991 And 1992 MY Vehicles

WARNING:
IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE FLAME NEAR THE FUEL LINES.

1. Raise vehicle on an appropriate hoist.

2. On Wrangler (YJ) vehicles: Support the transmission and remove the skid plate.





3. Remove and discard the nuts, bolts and gasket at the front of the converter and the exhaust pipe clamp at the rear (Figure 1).

NOTE:
Use penetrating oil if necessary.

4. Place a block of wood against the rear of the converter and drive the converter forward to disengage the alignment tab on the converter pipe from the alignment slot on the muffler.

NOTE:
If the converter does not move forward, it may be necessary to heat the converter to muffler connection with an oxyacetylene torch until the metal becomes cherry red.

5. Twist the converter back and forth to separate it from the muffler.

6. Install the new converter into the muffler until the alignment tab is inserted into the alignment slot.

7. Using the provided gasket, nuts and bolts, attach the converter to the front exhaust pipe. Do not tighten the bolts.

8. Install and tighten the new exhaust pipe clamp, at the muffler to converter connection, to 45 ft-lbs (61 N.m).

9. Tighten the converter to front exhaust pipe bolts to 25 ft-lbs (34 N.m).

10. On Wrangler (YJ) vehicles: Install the skid plate.

11. Lower the vehicle.