Service Procedure

CATALYTIC CONVERTER:

PART I - INSPECTION

1. Raise vehicle on hoist.

2. Refer to Figure 1 for location of catalytic converter part number.
3.a. If the converter is Part Number 25056620, it should not be replaced. Lower the vehicle and proceed to PART III for installation of campaign identification label.

b. If the converter is not identified as Part Number 25056620, it should be replaced as instructed in PART II of this SERVICE PROCEDURE.

PART II - CONVERTER REPLACEMENT

CAUTION: The catalytic converter beads contain platinum, palladium and/or rhodium. Additionally, the beads may be finely coated with lead compounds. Therefore, precautions should be taken to minimize dust generation during the replacement procedure. These precautions include:

A. Catalyst dust should be controlled by wetting with water prior to bead removal as described in Step 4 of PART IICONVERTER REPLACEMENT.

B. The use of a suitable dust mask, rubber gloves and safety glasses is recommended when handling catalyst beads.

C. Applicable OSHA standards should be reviewed.

D. Allow converter to cool before handling.

1. Loosen clamp and disconnect AIR pipe from converter.

2. Disconnect intermediate exhaust pipe and hanger from rear of converter.
3. Remove clamp and disconnect converter from front exhaust pipe.

4. Stand the old converter upright on the inlet end and pour 16 ounces of water into the outlet end to control catalyst dust.

CATALYTIC CONVERTER:

5. Using a hammer and chisel, remove the fill hole plug from the lower bed (the smooth side of the converter is the lower bed side). See Figure 1.

6. Hold the converter over a clean pan (J-34155-2) and empty the catalyst beads by shaking.

It may be necessary to tap the converter belt flange with a hammer to loosen the beads.

7. Pour the beads into a sifting pan (J-34155-1) and sift to remove undersized beads.

Unusable beads and dust can be returned via exchange program described in WDDGM Bulletin IB NO. 83-138.

8. Prop the new converter up at a 45 degree angle with the lower bed fill hole at the top.

BEADS REPLACEMENT:

9. Using funnel J-34155-3, pour the sifted beads into the lower bed of the new converter (see Figure 2). Tap belt flange with rubber mallet to allow beads to settle. Continue filling and tapping until converter is full. If additional beads are required to completely fill the lower bed, it will be necessary to obtain a lower bed bead kit from the parts department.

Excess beads from the kit should be saved in a clean container for future use.
10. Lay the converter down on a flat surface with the lower bed fill hole on top.

11. Insert the fill plug into the lower bed fill hole. The fill plug outer rim must rest against the converter body.

PLUG INSTALLATION:

12. Insert tool J-34188 into fill plug and tighten to a torque 47 N-m (35 ft.lb.) (see Figure 3).
13. Install new converter in vehicle reversing removal procedure (Steps 1, 2, and 3) and using new bolts and clamp as required. Torque front clamp nuts to 35 N-m (26 ft.lb.), intermediate pipe to converter bolts to 20 N-m (15 ft.lb.) and hanger to converter bolts to 52 N-m (38 ft.lb.).

14. Lower vehicle and proceed to PART III (page 5) for installation of campaign identification label.