Service Procedure For 1993, 1994 and 1995 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 the U-bolt clamps from the exhaust pipe and muffler connections at the front (Figure 2) and rear (Figure 3) of the catalytic converter.

4. Heat the catalytic converter to muffler connection with an oxyacetylene torch until the metal becomes cherry red.

5. While the metal is still cherry red, twist the muffler assembly back and forth to separate it from the converter.

6. Disconnect the front exhaust pipe from the catalytic converter. If necessary, heat the pipe connection as described above.

7. Connect the supplied catalytic converter to the front exhaust pipe. Use one of the supplied clamps and tighten the nuts to 45 ft-lbs (61 N.m).

8. Install the muffler on to the catalytic converter until the alignment tab is inserted into the alignment slot.

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

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

11. Lower the vehicle.