The first step to work on a Catalytic Converter requires the placement of safety stands beneath the raised vehicle. Start by taking out the transmission rear support and removing the electrical connection for the
Oxygen Sensor (02S). Take off the exhaust manifold pipe nuts and their corresponding seals. The
Muffler front flange nuts need removal when servicing the 4.3l and 5.0l models with a 135 inch wheelbase. Maintenance on the exhaust system for 5.7l and 7.4l with 135 inch wheelbase requires loosening the front Muffler clamp then removing the front exhaust flange retaining nuts and gasket. The 4.3l and 5.0l with a 155-inch wheelbase as well as the 6.5l diesel require removal of the converter assembly's rear flange nuts. Lubricate the clamp near the Muffler front then remove the flange retaining nuts and gasket from both the exhaust and Muffler flange. Owners of the 5.7l and 7.4l cutaway and rv must remove exhaust flange retaining nuts and gasket from the Muffler's front flange. The
Exhaust Hangers must be removed before removing the Catalytic Converter and its attached oxygen sensors from the vehicle. Install the required oxygen sensors first and apply gm p/n 9985020 sealer or equivalent product to slip joint fittings during installation. Place the front Muffler pipe's Catalytic Converter assembly where it belongs after also installing needed exhaust hangers. When installing the exhaust flange retaining nuts and gasket on 5.7l, 7.4l cutaway, and rv models you must perform this task without applying any torque to the nuts. The installation process requires performing this sequence again for the 5.7l and 7.4l with 155 inch and 135 inch wheelbases alongside the 4.3l and 5.0l with 155 inch and 6.5l diesel at the converter assembly end while avoiding any nut tightening. The new seal and exhaust pipe flange should be installed onto exhaust manifold studs following torque settings of 65 nm (48 ft. Lbs.) on the exhaust pipe flange to exhaust manifold nuts. Verify exhaust system alignment then tighten all exhaust pipe clamps to 70 nm (52 ft. Lbs.) while setting the exhaust flange retaining nuts to the Muffler at 48 nm (35 ft. Lbs.). After connecting the Oxygen Sensor (02S) electrical connection you need to reinstall the transmission support and must check the exhaust system to ensure all components are properly aligned before removing safety stands to lower the vehicle.