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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1054 (Engine Exhaust System) >> Repair Instructions >> Muffler Replacement (6.0L, 6.6L, and 8.1L Engines) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the spare tire, if necessary.
  3. Install adjustable jack stands under the rear axle, if necessary.
  4. If equipped with a 8.6 or 9.5 inch ring gear, remove the rear axle vent hose from the rear axle, if necessary.
    Fig 1: Rear Axle Vent Hose (8.6 or 9.5 Inch Ring Gear)
    GM692548Courtesy of GENERAL MOTORS CORP.
  5. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary.
    6. Fig 2: Rear Axle Vent Hose (10.5 Inch Ring Gear)
    GM695038Courtesy of GENERAL MOTORS CORP.
  6. If equipped with a 10.5 inch ring gear, remove the rear axle vent hose from the rear axle, if necessary.
  7. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary.
    8. Fig 3: Rear Shock Absorber Bolts And Nuts (6.0L, 6.6L, and 8.1L Engines)
    GM665315Courtesy of GENERAL MOTORS CORP.
  8. Remove the rear shock absorbers lower bolts and nuts, if necessary.
  9. Lower the rear axle using the adjustable jack stands, if necessary.
    10. Fig 4: Exhaust Muffler Nuts (6.0L and 8.1L Engines)
    GM858609Courtesy of GENERAL MOTORS CORP.
  10. If equipped with a 6.0L or 8.1L engine, remove the exhaust muffler nuts.
  11. Loosen the exhaust pipe clamp.
  12. With the aid of an assistant, support the exhaust muffler.
    13. Fig 5: Exhaust Muffler Nuts (6.0L, 6.6L, and 8.1L Engines)
    GM694338Courtesy of GENERAL MOTORS CORP.
  13. If equipped with a 6.6L engine, remove the exhaust muffler nuts.
  14. With the aid of an assistant, support the exhaust muffler.
    15. Fig 6: Exhaust Muffler (6.0L and 8.1L Engines)
    GM858603Courtesy of GENERAL MOTORS CORP.
  15. If equipped with a 6.0L or 8.1L engine, remove the insulators from the frame hangers.
  16. With the aid of an assistant, slide the muffler rearward in order to remove the muffler from the catalytic converter.
  17. Remove the insulators from the muffler hangers.
  18. Remove the exhaust manifold pipe gasket, if necessary.
    19. Fig 7: Exhaust Insulators (6.6L Engine)
    GM694340Courtesy of GENERAL MOTORS CORP.
  19. If equipped with a 6.6L engine, remove the insulators from the frame hangers.
  20. With the aid of an assistant, slide the muffler rearward in order to remove the muffler from the exhaust muffler pipe.
  21. Remove the exhaust muffler gasket, if necessary.
  22. Remove the insulators from the muffler hangers.
    23. Fig 8: Oxygen Sensor (6.0L and 8.1L Engines)
    GM695550Courtesy of GENERAL MOTORS CORP.
  23. If equipped with a 6.0L or 8.1L engine, remove the oxygen sensor if the muffler is being replaced.
  24. If the muffler is NOT being replaced as an assembly, the band clamp MUST be replaced. Perform the following:
    1. Mark the position of the band clamp on the intermediate exhaust pipe.
    2. Remove the band clamp from the exhaust pipe by grinding the weld.
    3. Install a NEW band clamp onto the exhaust pipe.
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