Muffler: Service and Repair

MUFFLER

REMOVAL





1. Raise vehicle.
2. Remove catalytic converter to muffler and resonator clamps (2).





3. Remove nuts (1) and tunnel reinforcement (2).





4. 5.7L/6.1 L Engine - Remove LH resonator and tailpipe assembly.
5. Remove isolators (4).
6. Remove muffler and tailpipe assembly (5) by twisting/turning while pulling assembly out of catalytic converters.

INSTALLATION





1. Position front exhaust pipe module clamps (2) on exhaust pipe assembly
2. Install exhaust pipe assembly into catalytic converters (3 and 4).

NOTE: Isolators will have an approximately 100 forward angle when installed.





3. Install isolators.
4. 5.7L/6.1 L Engine - Install LH rear resonator and tailpipe assembly.

NOTE: Check for proper alignment and clearance to underbody and engine compartment components before tightening clamps.

5. Tighten band clamps to 61 Nm (45 ft. lbs.).





6. Install tunnel reinforcement (2) and nuts (1).
Tighten nuts to 25 Nm (215 inch lbs.)
7. Check clearance between muffler and resonator assembly and fuel tank. Clearance is 14 mm (0.55 inch) for V8 engine and 16 mm (0.62 inch) for V6 engine.
8. Check clearance at rear tunnel reinforcement. Clearance is 15 - 20 mm (0.59 - 0.78 inch).
9. The tailpipe should be centered in the rear fascia opening.
10. Adjust clearance as necessary
11. Lower vehicle.
12. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.