Removal Procedure

CAUTION: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

CAUTION: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

An accumulation of dirt and corrosion may make removing exhaust components difficult. Applying a penetrating oil on the threads of the bolts may assist in the removal of these components.

Raise the vehicle. Refer to JACKING AND LIFTING - 2WD in General Information.
Support the catalytic converter assembly.

Fig 1: Removing Catalytic Converter Assembly (A4WD)
Courtesy of GENERAL MOTORS CORP.
Remove the 3 oxygen sensor electrical connections and clips.
Remove the nuts from the muffler flange bolts.

Fig 2: Removing Nuts From Muffler Flange Bolts (A4WD)
Courtesy of GENERAL MOTORS CORP.
Remove the nuts from the exhaust manifold studs (right side).
Disconnect the collars from the exhaust manifold studs (right side).

Fig 3: Disconnecting Collars From Exhaust Manifold Studs - Right Side (A4WD)
Courtesy of GENERAL MOTORS CORP.
Remove the nuts from the exhaust manifold studs (left hand).
Disconnect the collars from the exhaust manifold studs (left side).

Fig 4: Disconnecting Collars From Exhaust Manifold Studs - Left Side (A4WD)
Courtesy of GENERAL MOTORS CORP.
Remove the catalytic converter assembly hanger from the transfer case.

Fig 5: Removing Catalytic Converter Assembly Hanger From Transfer Case (A4WD)
Courtesy of GENERAL MOTORS CORP.
Remove the catalytic converter assembly hanger from the catalytic converter.
Separate the catalytic converter assembly from the muffler assembly.
Separate the catalytic converter assembly from the exhaust manifolds.
NOTE: Do not damage the oxygen sensors when removing the catalytic converter.
Remove the catalytic converter assembly from the vehicle by doing the following:
1. 13.1. Lower the rear of the catalytic converter assembly.
2. 13.2. Move the catalytic converter assembly toward the rear of the vehicle.
3. 13.3. Rotate and lower the catalytic converter assembly behind the transfer case support crossmember.
Remove the oxygen sensors from the catalytic converter assembly.