Muffler: Service and Repair

Exhaust Muffler Replacement (LH9) (5.3L)

Removal Procedure
Warning: Refer to Exhaust Service Warning (Exhaust Service Warning).

Warning: Refer to Protective Goggles and Glove Warning (Protective Goggles and Glove Warning).


1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Description and Operation).
2. Remove the spare tire. Refer to Spare Tire Carrier Replacement (Service and Repair).





Note: Use care not to over extend the rear brake hose.

3. Complete the following in order to gain clearance to remove the muffler:

1. Remove the lower shock absorber nuts (9) and bolts (8).
2. Remove the rear axle vent tube from the body.
3. Unfasten the brake lines from the rear axle. Do not open the connections.
4. Place a jack stand under the rear axle.
5. Remove both rearward spring shackle bolts and nuts.
6. Remove the propeller shaft center support bearing bolts.
7. Remove the heat shield located above the muffler assembly to converter Y pipe.

Note: only drop the axle enough to gain clearance.

8. Lower the rear axle to allow the exhaust system clearance.




4. Remove the catalytic converter nuts (1).
5. Loosen the front exhaust muffler pipe at the catalytic converter clamp (2).
6. Separate the front exhaust muffler pipe hanger from the insulator.
7. Separate the front exhaust muffler pipe from the catalytic converters.





Note: Do not use oil base lubricants.

8. Apply a soapy solution to the exhaust pipe hanger rods (3) in order to ease the removal of the exhaust hangers (1).
9. Pry the exhaust hangers (1) free from the exhaust pipe hanger rods (3).
10. Complete the following in order to remove the muffler from the vehicle:

Note: It may be necessary to rotate the Muffler in order to gain clearance.

1. Slide the muffler rearward from the catalytic converter.
2. Carefully remove the muffler rearward from the vehicle.

Installation Procedure

1. Complete the following in order to install the muffler to the vehicle:

Note: It may be necessary to rotate the Muffler in order to gain clearance.

1. Carefully insert the muffler over the rear axle until the Y flange is near the catalytic converter.
2. Slide the muffler forward into position, aligning the studs with the rear of the catalytic converter.





Note: Do not use oil base lubricants.

2. Apply a soapy solution to the following in order to ease the installation of the hangers (1):

* The inner diameter of the exhaust pipe hanger (1)
* The exhaust pipe hanger rod (3)




3. Position the front exhaust muffler pipe to the catalytic converters.
4. Install the front exhaust muffler pipe to the front exhaust insulator.

Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the catalytic converter nuts (1) and tighten to 45 Nm(33 lb ft).
6. Tighten the exhaust muffler clamp at the catalytic converter (2) and tighten to 43 Nm (32 lb ft).
7. Raise the rear axle.
8. Install both rearward spring shackle bolts and nuts. Refer to Leaf Spring Replacement (Rear Suspension Leaf Spring)




9. Install the lower shock absorber bolts (8) and nuts (9) and tighten to 95 Nm (70 lb ft).
10. Remove the jack stand from under the rear axle.
11. Install the heat shield located above the muffler assembly to converter Y pipe.
12. Install the propeller shaft center support bearing bolts. Refer to Two-Piece Propeller Shaft Replacement (Two-Piece Propeller Shaft Replacement).
13. Fasten the brake lines to the rear axle. Refer to Rear Brake Hose Replacement (Rear Brake Hose Replacement).
14. Install the rear axle vent tube to the body.
15. Install the spare tire. Refer to Spare Tire Carrier Replacement (Service and Repair).
16. Inspect the exhaust system for leaks and underbody contact.
17. Lower the vehicle.