Rear Exhaust System Replacement Heavy Duty-6.0L

Important: The slip joint clamp must be replaced whenever the slip joint is disconnected.

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the protective shields as necessary.



3. Disconnect the electrical connection from the oxygen sensor.



4. Loosen the clamp at the slip joint (2).
5. Remove the nuts (5) at the rear exhaust system flange.



6. Disconnect the exhaust hangers from the rear exhaust system.



7. Support the rear axle with jack stands.
8. Remove the upper shock absorber bolts/nuts.
9. Lower the rear axle.
10. Slide the rear exhaust system rearward in order to disengage the flange and the slip joint.
11. Remove the rear exhaust system.
12. Remove and discard the slip joint clamp.
13. Transfer the oxygen sensor if you are replacing the rear exhaust system.

1. Install a new slip joint clamp.
2. Install the rear exhaust system.
3. Slide the rear exhaust system forward in order to engage the flange and the slip joint.
4. Raise the rear axle.
5. Install the upper shock absorber bolts/nuts.
6. Remove the rear axle support.



7. Connect the exhaust hangers to the rear exhaust system.




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.

8. Install the nuts (5) to the rear exhaust system flange.

Tighten
Tighten the nuts to 40 N·m (30 lb ft).

9. Tighten the clamp (2) at the slip joint.

Tighten
Tighten the nut to 40 N·m (30 lb ft).




10. Connect the electrical connector to the oxygen sensor.
11. Remove the safety stands.
12. Lower the vehicle.

Rear Exhaust System Replacement Light Duty-4.3L, 4.8L, and 5.3L

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



2. Remove the flange stud nuts (2) at the junction of the rear exhaust system and the catalytic convertor.
3. Disconnect the exhaust hangers for the rear exhaust system.



4. Remove the rear exhaust system.

1. Install the rear exhaust system.
2. Connect the exhaust hangers to the rear exhaust system.




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.

3. Install the flange stud nuts (2) at the junction of the rear exhaust system and the catalytic convertor.

Tighten
Tighten the nuts to 40 N·m(30 lb  ft).

4. Remove the safety stands.
5. Lower the vehicle.