Tools Required

J 29800 Cut-Off Tool

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.




Important: A service muffler is required when replacing the intermediate pipe/resonator on an originally equipped welded system.

2. Support the converter.
3. Support the muffler.
4. Remove the intermediate pipe/resonator assembly hanger.



5. Cut the pipe close to the weld at the converter and the muffler using a J 29800 or a BT 8252.



6. Remove the muffler hangers.
7. Remove the intermediate pipe/resonator assembly.
8. Remove the muffler.

1. Loosely install the muffler with a U-bolt type clamp onto the intermediate pipe/resonator and the hangers.
2. Loosely install the intermediate pipe/resonator to the converter using a U-bolt type clamp.
3. Loosely install the muffler onto the hangers.
4. Install the intermediate pipe/resonator hanger.
5. Align the system for proper clearances. Refer to Exhaust System Alignment.
6. Tighten the pipe clamps.
7. Tighten the hanger fasteners.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

8. Install the clamp nuts

Tighten
Tighten the nuts to 40 N·m (30 lb ft).