Muffler: Service and Repair

Exhaust Muffler Replacement (1500 Series V6 or V8)

Removal Procedure




1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
2. Lower the spare tire.
3. Remove the catalytic converter to exhaust muffler nuts.




4. If equipped with a exhaust muffler clamp (Norma), loosen the catalytic to exhaust muffler clamp nut (1).




5. If equipped with a 4.8L engine, perform the following steps, otherwise proceed to step 7.
6. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease removal.
7. With the aid of an assistant, remove the insulators (1, 2) from the front and rear muffler assembly hangers.




8. Remove the insulator (1) from the intermediate muffler assembly hanger and remove the muffler assembly.




9. If equipped with a 5.3L, or a 6.0L engine, lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease removal.
10. With the aid of an assistant, remove the insulators (1, 2) from the front and rear muffler assembly hangers.





Caution: During removal or installation, do not over extend the flex couple as internal damage may occur.

11. Remove the insulators (1) from the intermediate muffler assembly hangers and remove the muffler assembly. Pull the muffler assembly rearward until the flange is able to clear the front frame crossmember, and remove the muffler toward the front of the vehicle.

Installation Procedure




1. If equipped with a 4.8L engine, perform the following steps, otherwise proceed to step 6.
2. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease installation.

Caution: During removal or installation, do not over extend the flex couple as internal damage may occur.

3. With the aid of an assistant, position and install the muffler assembly.
4. Install the insulators (1, 2) to the front and rear muffler assembly hangers.




5. Install the insulator (1) to the intermediate muffler assembly hanger.




6. If equipped with a 5.3L, or a 6.0L engine, lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease installation.
7. With the aid of an assistant, position and install the muffler assembly.
8. Install the insulators (1, 2) to the front and rear muffler assembly hangers.




9. Install the insulator (1) to the intermediate muffler assembly hanger.





Caution: Refer to Fastener Caution Fastener Caution.

10. Install the catalytic converter to exhaust muffler nuts and tighten to 45 Nm (33 lb ft).




11. For mufflers using an exhaust clamp (Norma), install the catalytic converter to the exhaust muffler and tighten clamp nut (1) to 28 Nm (21 lb ft).
12. Return the spare tire to the original position.
13. Lower the vehicle.