3-49. MUFFLER AND CATALYTIC CONVERTER REPLACEMENT
This task covers:
a. Removal
b. Installation
a. Removal
INITIAL SETUP:
Tools
General mechanic’s tool kit:
automotive (Appendix B, Item 1)
Maintenance and repair shop equipment:
automotive (Appendix B, Item 2)
Material Parts
Nine locknuts (Appendix G, Item 157)
Gasket (Appendix G, Item 55)
Seven lockwashers (Appendix G, Item 206)
Manual References
TM 9-2320-387-24P
Equipment Condition
Tailpipe removed (para. 3-48).
General Safety Instructions
Do not touch hot exhaust system components with
bare hands.
Maintenance Level
Unit
b. Installation
TM 9-2320-387-24-1
3-92
Change 1
WARNING
Do not touch hot exhaust system components with bare hands.
Severe injury may result.
CAUTION
Support muffler and catalytic converter during replacement.
Failure to do so may result in damage to equipment.
1.
Remove two clamps (14) and heat shield (15) from crossover pipe (17).
2.
Remove two nuts (13), U-bolt (23), and support bracket (20) from heat shield (10) and catalytic
converter (24).
3.
Remove two nuts (6), lockwashers (5), and washers (4) from heat shield (10). Discard lockwashers (5).
4.
Remove capscrew (7), lockwasher (8), and Y-clip (9) at location A and screw (12), lockwashers (11)
and (28), and nut (29) at location B and heat shield (10) from bracket (27). Discard lockwashers (8),
(11), and (28).
5.
Remove two nuts (25), washers (26), capscrews (31), washers (30), and bracket (27) from muffler (32).
6.
Remove three locknuts (18), washers (19), capscrews (22), and washers (21) from catalytic
converter (24) and crossover pipe (17). Discard locknuts (18).
7.
Remove two nuts (40), lockwashers (39), and U-bolt (37) from catalytic converter (24) and support
bracket (38). Discard lockwashers (39).
8.
Remove gasket (16) by pulling catalytic converter (24) towards rear of vehicle. Discard gasket (16).
NOTE
It may be necessary to lower rear propeller shaft (para. 6-4) to gain
access to locknuts on muffler hanger.
9.
Remove four locknuts (3), washers (2), capscrews (33), washers (34), two retaining plates (35), and
muffler (32) from muffler hanger (1). Discard locknuts (3).
10.
Remove two locknuts (41), washers (46), capscrews (44), washers (43), insulator (36), retaining
plate (45), and bracket (42) from muffler (32). Discard locknuts (41).
1.
Install bracket (42), insulator (36), and retaining plate (45) on muffler (32) with two washers (43),
capscrews (44), washers (46), and locknuts (41). Tighten locknuts (41) to 10 lb-ft (14 N•m).
2.
Install muffler (32) and two retaining plates (35) on muffler hanger (1) with four washers (34),
capscrews (33), washers (2), and locknuts (3).
3.
Install catalytic converter (24) on support bracket (38) with U-bolt (37), two lockwashers (39), and
nuts (40).
