Catalytic Converter: Service and Repair

REMOVAL

Catalytic Converter Removal:

1. Disconnect both oxygen sensor connectors. Mark each sensor connector for identification.

Catalytic Converter Removal:

2. Support the exhaust assembly with a lifting fixture. Approx. exhaust assembly weight (120 lbs.)
3. Unscrew left and right transmission brackets at catalytic converter.

Catalytic Converter Removal:

4. Unbolt the catalytic converters at left and right manifolds.

Catalytic Converter Removal:

5. Loosen the left and right brackets on rear axle carrier. Disconnect the rubber rings.

Catalytic Converter Removal:

6. Unscrew both holders on the final muffler at rear.
7. Carefully lower the exhaust assembly.

Catalytic Converter Removal:

8. Unscrew left and right rear catalytic convert flange bolts.
9. Remove the muffler assembly.

INSTALLATION

Catalytic Converter Removal:

1. With new rear converter flange seals in position, reconnect the muffler and catalytic converter. The gap between flanges must be aligned parallel. Install the flange bolts snugly, but do not torque at this time.
2. Install new spherical seals and flange gaskets at the exhaust manifolds.
3. Lift the exhaust assembly into place.

Catalytic Converter Removal:

4. Install the rubber rings at left and right rear axle carrier brackets.
5. Install bolts for manifold-converter connection. Do not tighten at this time.

Catalytic Converter Removal:

6. Reinstall both holders for the final muffler. Do not tighten at this time.
7. Reinstall bolts for left and right transmission bracket. Do not tighten at this time.

Catalytic Converter Removal:

8. Tighten flange with spherical seal (1), left and right outer pipes to 18 ft. lbs.
9. Tighten flange with gasket (2), left and right inner pipes to 18 ft. lbs.
10. Loosen converter-muffler flange bolts. Now tighten to 16 ft. lbs.

Catalytic Converter Removal:

11. Preload rubber rings by moving the bars on the axle carrier up and torque to 16 ft. lbs.

Catalytic Converter Removal:

12. Preload the rear muffler rubber mounts in forward direction by a distance of 15 mm (A). Torque to 16 ft. lbs.
13. Torque left and right transmission brackets to 16 ft. lbs.
14. Reconnect the oxygen sensors.

Catalytic Converter Removal:

15. Check the position of tailpipes in body op ing. If necessary, loosen flanges and align the muffler assembly.
16. Check for exhaust leaks and correct exhaust assembly alignment.