Removal and installation

Exhaust pipe

CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.

REMOVAL

(1) Raise and support the vehicle.

(2) Saturate the bolts and nuts with Mopart Rust Penetrant. Allow 5 minutes for penetration.

(3) Disconnect the oxygen sensor(s).

(4) Remove the exhaust manifold-to-exhaust pipe nuts (Fig. 7) (Fig. 8) (Fig. 9).

(5) Remove exhaust pipe/converter to muffler exhaust clamp.

(6) Disconnect the exhaust pipe/catalytic converter from muffler.

(7) Remove the exhaust pipe.

Fig. 7 Exhaust Pipe to Manifold Connection-(5.2L and 5.9L)

1 - BOLT

2 - RETAINER

3 - EXHAUST MANIFOLD

4 - NUT

5 - EXHAUST PIPE

Fig. 8 Exhaust Pipe(s) to Manifold Connection- (4.7L Federal Models)

1 - BOLT

2 - RETAINER

3 - EXHAUST MANIFOLD

4 - NUT

5 - EXHAUST PIPE

Fig. 9 Exhaust Pipe(s) to Manifold Connection- (4.7L California Models)

1 - BOLT

2 - RETAINER

3 - EXHAUST MANIFOLD

4 - NUT

5 - EXHAUST PIPE

INSTALLATION

(1) Align and connect the exhaust pipe/catalytic converter to the muffler. Install exhaust clamp and tighten clamp nuts to 42 N*m (31 ft. lbs.) torque.

(2) Connect the exhaust pipe(s) to the exhaust manifold. Tighten the nuts to 34 N*m (25 ft. lbs.) torque.

(3) Connect oxygen sensor connector(s).

(4) Lower the vehicle.

(5) Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels.

Adjust the alignment, if needed.

Catalytic converter

NOTE: Neither the inline catalytic converter nor the mini catalytic converters (California emission vehicles only) are serviceable separately from the exhaust pipe. Refer to Exhaust Pipe for removal / installation procedure.

Muffler

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

CAUTION: When servicing or replacing exhaust system components, be sure to disconnect all oxygen sensor connectors. Allowing the exhaust system to hang by the harness will damage the wiring and/or sensor.

REMOVAL

(1) Disconnect battery negative cable.

(2) Raise vehicle on hoist.

(3) Remove muffler to exhaust pipe/catalytic converter and tailpipe clamps (Fig. 10).

(4) Remove tailpipe from hanger isolator. Heat muffler to tailpipe with an oxygen/acetylene torch and twist tailpipe out of muffler.

(5) Disconnect muffler from hanger isolators (Fig.

10).

(6) Heat muffler to exhaust pipe/catalytic converter connection and twist muffler off of converter pipe.

INSTALLATION

(1) Install muffler to exhaust pipe/catalytic converter and tailpipe. Install exhaust clamps and start nuts by hand.

(2) Connect muffler to rear muffler hanger.

(3) Connect tailpipe to rear hanger.

(4) Align muffler and tighten exhaust clamp nuts to 42 N*m (31 ft. lbs.).

(5) Lower vehicle and connect battery negative cable.

(6) Start engine and check for exhaust leaks.

Fig. 10 Muffler Removal/Installation

1 - CATALYTIC CONVERTER WITH PIPE

2 - REAR MUFFLER HANGER

3 - MUFFLER

4 - CLAMP

Tailpipe

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

CAUTION: When servicing or replacing exhaust system components, be sure to disconnect all oxygen sensor connectors. Allowing the exhaust system to hang by the harness will damage the wiring and/or sensor.

REMOVAL

(1) Disconnect battery negative cable.

(2) Raise vehicle on hoist.

(3) Disconnect tailpipe from rear hanger bracket (Fig. 11).

(4) Remove muffler to tailpipe exhaust clamp (Fig. 11).

(5) Heat connection with an oxygen/acetylene torch and twist tailpipe out of muffler.

INSTALLATION

(1) Install tailpipe to muffler. Install exhaust clamp and start nuts by hand.

(2) Connect tailpipe hanger.

(3) Align tailpipe and tighten exhaust clamp nuts to 42 N*m (31 ft. lbs.).

(4) Lower vehicle and connect battery negative cable.

(5) Start engine and check for exhaust leaks.

Fig. 11 Tailipipe Removal/Installation

1 - MUFFLER

2 - TAILPIPE HANGER INSULATOR

3 - TAILPIPE HANGER

4 - TAILPIPE

5 - CLAMP

Heat shields

REMOVAL

(1) Raise and support the vehicle.

(2) Remove the screws and nuts holding the heat shields to the frame and floor pan (Fig. 12) (Fig. 13) (Fig. 14). When removing muffler heat shield, the muffler front and rear support hangers must be removed first (Fig. 15). Be sure to disconnect both oxygen sensor connectors.

(3) Slide the shield out around the exhaust system.

INSTALLATION

(1) Position the heat shields to the floor pan or the frame and install the screws and nuts.

(2) Tighten the screws/nuts to 7 N*m (60 in. lbs.) torque. Tighten the muffler hangers to 23 N*m (200 in. lbs.) (3) Lower the vehicle.

Fig. 12 Front and Rear Floor Pan/Converter Shields

1 - REAR FLOOR PAN/CONVERTER SHIELD

2 - FRONT FLOOR PAN/CONVERTER SHIELD

Fig. 13 Rear Compartment/Tailpipe Heat Shield

1 - REAR COMPARTMENT TAILPIPE SHIELD

Fig. 14 Left and Right Dash Heat Shield

1 - LEFT DASH HEAT SHIELD

2 - RIGHT DASH HEAT SHIELD

Fig. 15 Muffler Heat Shield

1 - MUFFLER HEAT SHIELD

2 - MUFFLER HANGERS

Specifications

Torque specifications