GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

The muffler is serviced as one piece from the catalytic converter to the tail pipe.

  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Notice: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.

  3. Use a utility stand in order to support the catalytic converter.

  4. Object Number: 739224  Size: SH
  5. Remove the catalytic converter bolts.
  6. Remove the catalytic converter gasket.

  7. Object Number: 260060  Size: SH
  8. Remove the exhaust hanger insulators from the exhaust pipes.
  9. Support and lower the rear crossmember. AWD models refer to Crossmember Replacement in Frame and Underbody.
  10. Remove the muffler and exhaust pipes towards the front of the vehicle and over the rear axle.
  11. Clean the catalytic converter flange and the muffler flange.

Installation Procedure

  1. Install the muffler and exhaust pipes over the rear axle and towards the rear of the vehicle.

  2. Object Number: 260060  Size: SH
  3. Install the exhaust hanger insulators to the exhaust pipes.
  4. Install rear crossover. AWD models refer to Crossmember Replacement in Frame and Underbody.

  5. Object Number: 739224  Size: SH
  6. Install a new catalytic converter gasket.
  7. Notice: Refer to Fastener Notice in the Preface section.

  8. Install the catalytic converter bolts.
  9. Tighten
    Tighten the catalytic converter bolts to 34 N·m (25 lb ft).

  10. Lower the vehicle.