Catalytic Converter Replacement 2WD

1. Raise the vehicle.
2. Support the catalytic converter.



3. Remove the four oxygen sensor electrical connections and clips.



4. Remove the nuts from the muffler flange bolts.
5. Remove the nuts from the exhaust manifold studs.
6. Remove the collars from the exhaust manifold studs.



7. Remove the catalytic converter pipe from the muffler.
8. Remove the catalytic converter pipe from the exhaust manifolds.
9. Lower the front of the catalytic converter pipe.
10. Remove the catalytic converter from the hanger.

Notice: Do not damage the oxygen sensors when removing the catalytic converter.

11. Remove the catalytic converter assembly from the vehicle.
12. Rotate the catalytic converter assembly over the rear of the transmission crossmember.

Notice: Do not damage the oxygen sensors when removing the catalytic converter.




1. Install the catalytic converter assembly to the hanger.
2. Install the seals onto the catalytic converter assembly and the exhaust manifold studs. Loosely install the nuts onto the exhaust manifold studs.



3. Install the catalytic converter and the gasket to the muffler.



4. Loosely install the nuts.

Tighten

•	Tighten the converter assembly-to-exhaust manifold nuts to 24 N·m (18 lb ft), in the proper sequence.

•	Tighten the converter-to-muffler nuts to 40 N·m (30 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




5. Install the four oxygen sensor electrical connections and clips.
6. Remove the support from the exhaust system assembly.
7. Lower the vehicle from the hoist.

Catalytic Converter Replacement All Wheel Drive

1. Raise the vehicle.
2. Support the vehicle with safety stands.
3. Support the catalytic converter assembly.



4. Remove the four oxygen sensor electrical connections and clips.



5. Remove the nuts from the muffler flange bolts.



6. Remove the nuts from the exhaust manifold studs.



7. Remove the catalytic converter hanger from the transfer case adapter.
8. Remove the catalytic converter hanger from the catalytic converter.
9. Separate the catalytic converter from the muffler.
10. Separate the catalytic converter assembly from the exhaust manifolds.

Notice: Do not damage the oxygen sensors when removing the catalytic converter.

11. Remove the catalytic converter assembly from the vehicle.
12. Lower the rear of the catalytic converter assembly.
13. Move the catalytic converter assembly toward the rear of the vehicle.
14. Rotate and lower the catalytic converter assembly behind the transfer case-support crossmember.
15. Remove the catalytic converter from the vehicle.

Notice: Do not damage the oxygen sensors when removing the catalytic converter.

1. Raise the catalytic converter assembly into the vehicle, from behind the transfer case support crossmember.
2. Rotate the catalytic converter assembly, while directing the left exhaust pipe between the torsion bar and the transmission.
3. Move the catalytic converter assembly toward the front of the vehicle.



4. Install the seals onto the catalytic converter assembly and the exhaust manifold studs. Loosely install the nuts onto the exhaust manifold studs.



5. Connect the catalytic converter and gasket to the muffler.
6. Loosely install the nuts.



7. Connect the converter hanger to the converter.



8. Connect the converter hanger to the transfer case adapter.

Tighten

•	Tighten the converter hanger bolts to 52 N·m (38 lb ft).

•	Tighten the converter assembly-to-exhaust manifold nuts to 24 N·m (18 lb ft) in the proper sequence.

•	Tighten the converter-to-muffler nuts to 40 N·m (30 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




9. Install the four oxygen sensor electrical connections and the clips.
10. Lower the vehicle from the hoist.