Muffler: Service and Repair

Muffler Replacement (4.81- and 5.31- Engines)

- Tools Required
- J 38185 Hose Clamp Pliers

Removal Procedure





1. Remove the rear tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
2. Remove the oil pan skid plate bolts and plate, if necessary.
3. Remove the spare tire.





4. If servicing a vehicle equipped with regular production option (RPO) Z55, disconnect the chassis harness from the following electrical connectors:
- Electronic suspension rear position sensor (1)
- Rear shock (2)

Important: Do not attempt to pry the rear suspension sensor link rod from the rear position sensor ball stud.
5. Remove the left and right sensor link rods from the sensors, perform the following:

5.1. Support the sensor lever with your hand
5.2. Twist the link rod in order to remove it from the ball stud
6. Install adjustable jack stands under the rear axle.





7. Remove the rear axle vent hose from the rear axle, if necessary.
8. Remove the vent hose swivel clip from the rear brake crossover pipe.





9. Remove the rear shock absorbers lower bolts and nuts.
10. Lower the rear axle slightly, using the adjustable jack stands, in order to remove the muffler.





11. Remove the exhaust muffler nuts.





12. Remove the muffler from the insulators.

Installation Procedure





1. Apply lubricant to the exhaust insulators in order to aid in installation.
2. Install the muffler to the insulators.





Notice: Refer to Fastener Notice in Cautions and Notices.

3. Install the exhaust muffler nuts.
- Tighten the nuts to 40 Nm (30 ft. lbs.).





4. Raise the rear axle, using the adjustable jackstands.
5. Install the lower bolts and nuts to the rear shock absorbers.
- Tighten the rear bolts to 95 Nm (70 ft. lbs.).
6. Remove the adjustable jack stands from under the rear axle.





7. Install the vent hose swivel clip to the rear brake crossover pipe.
8. Install the rear axle vent hose to the rear axle, if necessary.





9. If servicing a vehicle, equipped with RPO Z55, install the left and right sensor link rods to the sensors. Using J 38185 install the link rods to the ball studs on the sensor levers.
10. Connect the chassis harness to the following electrical connectors:
- Electronic suspension rear position sensor (1)
- Rear shock (2)
11. Install the spare tire.





12. Install the oil pan skid plate and bolts, if necessary.
- Tighten the bolts to 20 Nm (15 ft. lbs.).
13. Install the rear tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.