Intermediate Pipe Replacement 6.0L

Caution: Refer to Exhaust Service Caution in the Preface section.

Caution: Refer to Protective Goggles and Glove Caution in the Preface section.

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Install adjustable jack stands under the front and rear of the intermediate pipe.
3. Loosen the exhaust muffler band clamps (2, 5).



4. Separate the left (1) and right (2) mufflers from the intermediate pipe (3).



5. Remove the exhaust pipe hanger lower bolts (3).



6. Remove the intermediate pipe-to-catalytic converter pipe nuts (2).
7. Remove the exhaust seal (3).
8. Lower the jack stands.
9. Remove the intermediate pipe from the jack stands.

Caution: Refer to Protective Goggles and Glove Caution in the Preface section.

Important: If reinstalling the original intermediate pipe, the tail pipe/muffler band clips must be replaced. Mark the position of the band clips on the intermediate exhaust pipe. Remove the band clips by grinding the welds. Install new band clips on the intermediate pipe. Position the new band clips using the alignment mark created previously.

1. Using a wire brush, clean the contact area of the left and right mufflers to the intermediate pipe.
2. Apply a small amount of lubricant on the intermediate pipes and the left and right mufflers



3. Position the intermediate pipe on the jack stands.
4. Raise the intermediate pipe and install the intermediate pipe.
5. Install the exhaust seal (3).



6. Install the intermediate pipe (3) to the left (1) and right (2) mufflers.

Important: When install the retaining nuts, hand tighten them. This will allow the proper alignment of the exhaust system for the final assembly procedure.

7. Install the retaining nuts (2).
8. Remove the adjustable jack stands.

Notice: Refer to Fastener Notice in the Preface section.




9. Tighten the exhaust muffler clamps (2, 5).

Tighten
Tighten the exhaust clamps bolts to 44 N·m (32 lb ft).




10. Tighten the intermediate pipe-to-catalytic converter pipe nuts (2).

Tighten
Tighten the intermediate pipe-to-catalytic converter pipe nuts to 16 N·m (12 lb ft).




11. Tighten the exhaust pipe hanger lower bolts (3).

Tighten
Tighten the exhaust pipe hanger bolts to 50 N·m (37 lb ft).

12. Lower the vehicle.

Intermediate Pipe Replacement 7.0L

Caution: Refer to Exhaust Service Caution in the Preface section.

Caution: Refer to Protective Goggles and Glove Caution in the Preface section.

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Install adjustable jack stands under the front and rear of the intermediate pipe.
3. Loosen the exhaust muffler band clamps (2, 5).



4. Separate the left (1) and right (2) mufflers from the intermediate pipe (3).



5. Remove the exhaust pipe hanger lower bolts (3).
6. Remove the intermediate pipe-to-catalytic converter pipe nuts and bolts.
7. Remove the exhaust pipe seal.
8. Lower the jack stands.
9. Remove the intermediate pipe from the jack stands.

Caution: Refer to Protective Goggles and Glove Caution in the Preface section.

Important: If reinstalling the original intermediate pipe, the tail pipe/muffler band clips must be replaced. Mark the position of the band clips on the intermediate exhaust pipe. Remove the band clips by grinding the welds. Install new band clips on the intermediate pipe. Position the new band clips using the alignment mark created previously.

1. Using a wire brush, clean the contact area of the left and right mufflers to the intermediate pipe.
2. Apply a small amount of lubricant on the intermediate pipes and the left and right mufflers
3. Position the intermediate pipe on the jack stands.
4. Raise the intermediate pipe and install the intermediate pipe.
5. Install the exhaust pipe seal.



6. Install the intermediate pipe (3) to the left (1) and right (2) mufflers.

Important: When install the retaining nuts, hand tighten them. This will allow the proper alignment of the exhaust system for the final assembly procedure.

7. Install the retaining nuts (2).
8. Remove the adjustable jack stands.

Notice: Refer to Fastener Notice in the Preface section.




9. Tighten the exhaust muffler clamps (2) and (5).

Tighten
Tighten the exhaust clamps bolts to 44 N·m (32 lb ft).

10. Tighten the intermediate pipe to catalytic converter pipe nuts and bolts.

Tighten
Tighten the intermediate pipe-to-catalytic converter pipe nuts and bolts to 25 N·m (18 lb ft).




11. Tighten the exhaust pipe hanger lower bolts (3).

Tighten
Tighten the exhaust pipe hanger bolts to 50 N·m (37 lb ft).

12. Lower the vehicle.