Muffler Replacement (2500/3500 Series w/6.0L)

Muffler Replacement (2500/3500 Series w/6.0L)

Removal Procedure





1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the spare tire, if necessary.
3. Install adjustable jack stands under the rear axle, if necessary.
4. If equipped with a 8.6 or a 9.5 inch ring gear, remove the rear axle vent hose from the rear axle, if necessary.
5. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary.




6. If equipped with a 10.5 inch ring gear, remove the rear axle vent hose from the rear axle, if necessary.
7. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary.




8. Remove the rear shock absorber lower bolts and nuts, if necessary.
9. Lower the rear axle using the adjustable jack stands, if necessary.




10. Remove the muffler to catalytic converter nuts.




11. If the vehicle is a non heavy duty (HD), perform the following steps, otherwise proceed to step 14:
12. Lubricate the 4 insulators where the muffler assembly hangers are inserted in order to ease removal.
13. With the aid of an assistant, remove the insulators (1-4) from the front, intermediate, and rear muffler assembly hangers and remove the muffler assembly.




14. If the vehicle is a heavy duty (HD) perform the following steps:
15. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease removal.
16. With the aid of an assistant, remove the insulators (1-3) from the front, intermediate, and rear muffler assembly hangers and remove the muffler assembly.



Installation Procedure





1. If the vehicle is a non HD, perform the following steps, otherwise proceed to step 5:
2. Lubricate the 4 insulators where the muffler assembly hangers are inserted in order to ease installation.
3. With the aid of an assistant, position and install the muffler assembly.
4. Install the insulators (1-4) to the front, intermediate, and rear muffler assembly hangers.




5. If the vehicle is a HD, perform the following steps:
6. 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 (1-3) to the front, intermediate, and rear muffler assembly hangers.





Notice: Refer to Fastener Notice .

9. Install the catalytic converter to exhaust muffler nuts.

Tighten the nuts to 45 N.m (33 lb ft).





10. Raise the rear axle using the adjustable jack stands, if necessary.
11. Install the rear shock absorber lower bolts and nuts, if necessary.

Tighten the bolts to 95 N.m (70 lb ft).





12. If equipped with a 10.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
13. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary.




14. If equipped with a 8.6 or a 9.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
15. Install the vent hose swivel clip to the rear brake crossover pipe, if necessary.
16. Remove the adjustable jack stands from under the rear axle, if necessary.
17. Install the spare tire, if necessary.
18. Lower the vehicle.