Catalytic Converter Replacement
Catalytic Converter Replacement
Removal Procedure
Warning: Refer to Protective Goggles and Glove Warning (Protective Goggles and Glove Warning).
Warning: Refer to Exhaust Service Warning (Service Precautions).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Remove the oil pan skid plate , if equipped. Refer to Oil Pan Skid Plate Replacement (2500/2500 with RPO NZZ) (Oil Pan Skid Plate Replacement (2500/2500 with RPO NZZ))Oil Pan Skid Plate Replacement (1500 with RPO NZZ) (Oil Pan Skid Plate Replacement (1500 with RPO NZZ)).
3. Remove the transmission crossmember. Refer to Transmission Support Crossmember Replacement (4WD 2500 Series) ()Transmission Support Crossmember Replacement (4WD 1500 Series) ()Transmission Support Crossmember Replacement (2WD 2500 Series) (Transmission Support Crossmember Replacement (2WD 2500 Series))Transmission Support Crossmember Replacement (2WD 1500 Series) (Transmission Support Crossmember Replacement (2WD 1500 Series)).
4. If replacing the three way catalytic converter remove the heated oxygen (HO2S) sensors (1 -5) otherwise disconnect the heated oxygen (HO2S) sensors harness connectors. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (Service and Repair) , Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (Service and Repair) , Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (Service and Repair) and Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (Service and Repair).
5. Remove the catalytic converter pipe to the exhaust manifold nuts (1).
6. Remove the catalytic converter to muffler nuts.
7. Remove the catalytic converter pipe assembly from the vehicle.
8. Remove the exhaust seals (2 and 3) and discard.
Installation Procedure
1. Install NEW exhaust manifold seals (2 and 3).
2. Install the catalytic converter pipe to the exhaust manifolds.
Caution: Refer to Fastener Caution (Fastener Caution).
3. Install the catalytic converter pipe to exhaust manifold nuts (1) and tighten to 50 Nm(37 lb ft).
4. Install the muffler to catalytic converter nutsand tighten the clamp bolt (1) to 45 Nm(33 lb ft).
5. Install the transmission crossmember. Refer to Transmission Support Crossmember Replacement (4WD 2500 Series) ()Transmission Support Crossmember Replacement (4WD 1500 Series) ()Transmission Support Crossmember Replacement (2WD 2500 Series) (Transmission Support Crossmember Replacement (2WD 2500 Series))Transmission Support Crossmember Replacement (2WD 1500 Series) (Transmission Support Crossmember Replacement (2WD 1500 Series)).
Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from as exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation.
6. If replacing the three way catalytic converter Install the heated oxygen (HO2S) sensors (1 -5) otherwise Connect the heated oxygen (HO2S) sensors harness connectors. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (Service and Repair) , Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (Service and Repair) , Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (Service and Repair) and Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (Service and Repair).
7. Install the oil pan skid plate if equipped. Refer to Oil Pan Skid Plate Replacement (2500/2500 with RPO NZZ) (Oil Pan Skid Plate Replacement (2500/2500 with RPO NZZ))Oil Pan Skid Plate Replacement (1500 with RPO NZZ) (Oil Pan Skid Plate Replacement (1500 with RPO NZZ)).
8. Lower the vehicle.
9. Inspect for exhaust leaks.