Muffler: Service and Repair

MUFFLER

REMOVAL

5.9L DIESEL ENGINE
1. Disconnect the battery negative cables.
2. Raise and support the vehicle.





3. Remove the muffler to tail pipe and extension pipe clamps.
4. Disconnect the muffler from the hanger isolators.
5. Disconnect the muffler from the tailpipe.
6. Disconnect the muffler from the extension pipe and remove from the vehicle.

INSTALLATION





1. Install the muffler hanger rods into the isolators.
2. Install the muffler into the extension pipe.
3. Install the muffler into the tail pipe.
4. Install the exhaust clamps, align the exhaust system, and tighten the exhaust clamps to 54.2 Nm (40 ft. lbs.) torque.
5. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 inch) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed.
6. Lower the vehicle.
7. Connect the battery negative cables.
8. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.