REMOVAL & INSTALLATION
See Figures 1, 2 and 3
Safety glasses should be worn at all times when working on or near the exhaust system. Older exhaust systems will almost always be covered with loose rust particles which will shower you when disturbed. These particles are more than a nuisance and could injure your eye.
- Raise and support the front of the truck safely using jackstands.
- Disconnect the oxygen sensor(s) electrical connector.
- Remove the oxygen sensor(s). Special oxygen sensor sockets are available to help make removal easier.
- Spray all fasteners which are to be disconnected using a penetrating oil.
- Remove the front pipe(s)-to-manifold(s) nuts and separate (pry, if necessary) the front pipe (usually a ball joint fitting) from the exhaust manifold(s).
- At the catalytic converter, loosen the front pipe-to-converter clamp nuts, then slide the clamp away from the converter and separate the front pipe from the converter.
Use a twisting motion to separate the front pipe-to-converter slip joint connection. If the front pipe cannot be removed from the catalytic converter, use a hammer (to loosen the connection) or wedge tool to separate the connection.
- Inspect the pipe for holes, damage or deterioration; if necessary, replace the front pipe.
- Installation is the reverse of removal.
Be sure to use a sealing compound, such as 1051249 or equivalent, at the slip joint connection.
- Lubricate the front pipe-to-manifold(s) studs/nuts and the front pipe-to-converter clamp threads. Torque the front pipe-to-exhaust manifold bolts to 15 ft. lbs. (20 Nm) and the front pipe-to-converter clamp nuts to 35 ft. lbs. (47 Nm).
- Install the oxygen sensor. Coat the threads with anti-seize compound before installing.
- Connect the oxygen sensor(s) electrical connector.
- Start the engine and check for exhaust leaks.