3-49. MUFFLER AND CATALYTIC CONVERTER REPLACEMENT (M1123 AND
“A2” VEHICLES ONLY)
This task covers:
a. Removal
b. Installation
WARNING
Do not touch hot exhaust system components with bare hands.
Severe injury will result.
CAUTION
Support muffler and catalytic converter during replacement.
Failure to do so may result in damage to equipment.
1.
Remove two clamps (12) and heat shield (13) from crossover pipe (14).
2.
Remove four nuts (7), two lockwashers (6), washers (5), and U-bolt (25) from heat shield (11),
support bracket (24), and muffler (26). Discard lockwashers (6).
3.
Loosen clamp (8) and remove heat shield (11) from catalytic converter (18).
4.
Remove two nuts (10), lockwashers (6), washers (9), and heat shield (4) from muffler (26). Discard
lockwashers (6).
5.
Remove three locknuts (16), washers (15), capscrews (23), and washers (15) from catalytic
converter (18) and crossover pipe (14). Discard locknuts (16).
6.
Remove two nuts (21), lockwashers (20), and U-bolt (17) from catalytic converter (18) and support
bracket (19). Discard lockwashers (20).
7.
Remove gasket (22) by pulling catalytic converter (18) towards rear of vehicle. Discard gasket (22).
NOTE
It may be necessary to lower rear propeller shaft (para 6-5) to gain
access to locknuts on muffler hanger.
8.
Remove four locknuts (2), washers (3), capscrews (27), washers (3), two retaining plates (28), and
muffler (26) from muffler hanger (1). Discard locknuts (2).
9.
Remove two locknuts (34), washers (31), capscrews (32), washers (31) insulator (29), retaining
plate (33), and bracket (30) from muffler (26). Discard locknuts (34).
1.
Install bracket (30), insulator (29) and retaining plate (33) on muffler (26) with two washers (31),
capscrews (32), washers (31), and locknuts (34). Tighten locknuts (34) to 10 lb-ft (14 N•m).
b. Installation
a. Removal
INITIAL SETUP:
Applicable Models
M997A2, M1025A2, M1035A2, M1043A2,
M1045A2, M1097A2, M1123
Tools
General mechanic’s tool kit:
automotive (Appendix B, Item 1)
Materials/Parts
Nine locknuts (Appendix G, Item 106)
Gasket (Appendix G, Item 37)
Six lockwashers (Appendix G, Item 108)
Manual References
TM 9-2320-280-24P
Equipment Condition
Tailpipe removed (para. 3-47).
General Safety Instructions
Do not touch hot exhaust system components with
bare hands.
TM 9-2320-280-20-2
3-90
Change 2
