Exhaust System: Service and Repair

Exhaust System





Material

CAUTION: Do not use oil or grease-based lubricants on the isolators. They may cause deterioration of the rubber.

CAUTION: Oil or grease-based lubricants on the isolators may cause the exhaust hanger insulator to separate from the exhaust hanger bracket during vehicle operation.

NOTE: Exhaust fasteners are of a torque-prevailing design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.

1. With the vehicle in NEUTRAL, position on a hoist.
2. Remove the parts in the order indicated in the illustrations and tables.





To remove individual parts, only carry out the listed steps:





3. To install, reverse the removal procedure.

















Exhaust System-4.0L and 4.6L, Early Production Vehicles

















Exhaust System-4.0L, Late Production Vehicles











Exhaust System-4.6L, Late Production Vehicles

4. Check and, if necessary, align the exhaust system.

Item 12: Catalytic Converter Assembly Removal Note

1. NOTE: If removing the converter assembly, the transmission crossmember must be removed.

Using a suitable jack, support the transmission.





2. Remove the heat shield bolts.





3. Remove the plastic shield from the RH side of the crossmember.





4. Remove the four upper crossmember bolts.





5. Remove the four lower crossmember bolts.





6. Remove the transmission mount nuts and the crossmember.
7. Use a suitable jackstand to support the catalytic converter near the rear outlet. Use caution removing the catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs.

Item 13: Catalyst Monitor Sensor Removal Note
1. If installing a new converter, remove the catalyst monitor sensors.

Item 14: Heated Oxygen Sensor Removal Note
1. If installing a new converter, remove the heated oxygen sensors.

Item 14: Heated Oxygen Sensor Installation Note
1. Make sure to apply anti-seize to the threads of the sensors before installation.

Item 13: Catalyst Monitor Sensor Installation Note
1. Make sure to apply anti-seize to the threads of the sensors before installation.

Item 12: Catalytic Converter Assembly Installation Note
1. Clean the mating surfaces of the manifold outlet flare and the catalytic converter inlet flare. Also clean the mating surfaces of the inlet pipe and the catalytic converter. Support the catalytic converter near the rear outlet. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs. To correctly seat the converter, alternately tighten the exhaust manifold-to-catalytic converter nuts to specification.
2. Install the crossmember. To install, reverse the removal procedure.

Item 7: Muffler Installation Note





1. Make sure that the tab on the muffler outlet pipe is seated inside the notch on the extension nine before tightening the exhaust clamp.