Muffler Replacement (1500 - w/RPOs LC9/LMG/LY5/L76)

Muffler Replacement (1500 - w/RPOs LC9/LMG/LY5/L76) (5.3L and 6.0L)

Tools Required

J 38185 Hose Clamp Pliers


Removal Procedure





1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Disconnect the chassis wiring harness electrical connector (1) from the right rear wheel speed sensor wiring harness electrical connector (2).
3. If the vehicle is equipped with regular production option (RPO) Z55, disconnect the chassis wiring harness electrical connector (3) from the right rear shock absorber.
4. If the vehicle is equipped with RPO Z55, disconnect the right rear air line from the shock absorber.
5. Remove the right rear wheel speed sensor wiring harness electrical connector clip from the frame.





Important: The rear axle wiring harness clip is a one way clip with a D-shape section. The clip can only be installed and/or removed in only one direction.


6. Remove the right rear wheel speed sensor wiring harness clips from the frame and the control arm bracket.

Important: Do not attempt to pry the rear suspension sensor link rod from the rear position sensor ball stud.


7. Disconnect the right rear automatic level control sensor link rod from the sensor. Perform the following:

1. Support the sensor lever with your hand.
2. Twist the link rod ball in order to separate it from the ball stud.

8. Install a suitable adjustable jack under the rear axle.
9. Remove the right axle tie rod bolt (2) and nut (1).




10. Remove the rear axle vent hose from the rear axle, if necessary.
11. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary.
12. Remove the right rear stabilizer shaft link to frame bolt and nut.
13. Remove the right rear stabilizer shaft link from the frame.
14. Remove the right rear shock absorber lower bolt (4) and nut (3).
15. Lower the right side of the rear axle using the adjustable jack in order to remove the muffler.




16. Remove the catalytic converter to muffler nuts.




17. Lubricate the insulators where the muffler assembly hangers are inserted in order to ease in removal.
18. With the aid of an assistant, remove the insulators from the exhaust system hangers (1, 2, and 3).




19. With the aid of an assistant, remove the insulator from the exhaust system hanger near the resonator.

Important: During removal, do not over extend the flex coupler as internal damage may occur.


20. Remove the muffler assembly.



Installation Procedure





1. Lubricate the insulators where the muffler assembly hangers are inserted for ease of installation.

Important: During installation, do not over extend the flex coupler as internal damage may occur.


2. With the aid of an assistant, install the muffler assembly.
3. With the aid of an assistant, install the insulators to the exhaust system hangers (1, 2, and 3).




4. Install the insulator to the exhaust system hanger near the resonator.





Notice: Refer to Fastener Notice .

5. Install the catalytic converter to muffler nuts.

Tighten the nuts to 45 N.m (33 lb ft).

6. Raise the rear axle into position using the adjustable jack.




7. Install the right rear shock absorber lower bolt and nut.

Tighten the bolt/nut to 95 N.m (70 lb ft).

8. Install the right rear stabilizer shaft link to the frame.
9. Install the right rear stabilizer shaft link to frame bolt and nut.

Tighten the bolt/nut to 65 N.m (48 lb ft).

10. Install the right rear axle tie rod bolt (2) and nut (1).

Tighten the bolt/nut to 105 N.m (77 lb ft).





11. Install the rear axle vent hose to the rear axle, if necessary.
12. Install the vent hose swivel clip to the rear brake crossover pipe, if necessary.
13. Using the J 38185 install the right rear link rod to the ball studs on the sensors.

Important: The rear axle wiring harness clip is a one way clip with a D-shape section. The clip can only be installed and/or removed in only one direction.


14. Install the right rear wheel speed sensor wiring harness clips to the frame and the control arm bracket.
15. Install the right rear wheel speed sensor wiring harness electrical connector clip to the frame.




16. If the vehicle is equipped with RPO Z55, connect the right rear air line to the shock absorber.
17. If the vehicle is equipped with RPO Z55, connect the chassis wiring harness electrical connector (3) to the right rear shock absorber.
18. Connect the chassis wiring harness electrical connector (1) to the right rear wheel speed sensor wiring harness electrical connector (2).
19. Lower the vehicle.