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Installation 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.
NOTE: Refer to Fastener Notice in Cautions and Notices.
  1. If the catalytic converter was replaced, perform the following:
    1. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensors.
    2. Install the oxygen sensors.

      Tighten:  Tighten the sensors to 42 N.m (31 lb ft).

    Fig 1: View Of Oxygen Sensors
    GM664954Courtesy of GENERAL MOTORS CORP.
    2. Fig 2: Exhaust Pipe Hanger Bracket (6.0L engine, With RPO Y91)
    GM858597Courtesy of GENERAL MOTORS CORP.
  2. If equipped with a 6.0L engine, with RPO Y91, install a NEW exhaust seal to the exhaust manifold.
  3. Install the catalytic converter.

    Slide the catalytic converter hanger into the exhaust pipe hanger bracket.

    4. Fig 3: Exhaust Pipe Hanger Bracket (6.0L and 8.1L Engines)
    GM858580Courtesy of GENERAL MOTORS CORP.
  4. Install a NEW exhaust seal to the exhaust manifold.
  5. Install the catalytic converter.

    Slide the catalytic converter hanger into the exhaust pipe hanger bracket.

    6. Fig 4: Left Exhaust Manifold Pipe Nuts (6.0L or 8.1L Engine)
    GM858568Courtesy of GENERAL MOTORS CORP.
  6. Install the left exhaust manifold pipe nuts.
  7. Tighten the right exhaust manifold pipe nuts.

    Tighten:  Tighten the nuts to 50 N.m (39 lb ft).

  8. Using the transmission jack, raise the transmission slightly.
    9. Fig 5: View Of Transmission & HO2S Sensor Electrical Connector
    GM665040Courtesy of GENERAL MOTORS CORP.
  9. Connect the oxygen sensor electrical connectors (1, 2).
  10. Connect the CPA retainers.
  11. Install the muffler. Refer to Muffler Replacement (4.3L, 4.8L, and 5.3L Engines)  or Muffler Replacement (6.0L, 6.6L, and 8.1L Engines) .
    12. Fig 6: Transmission Support Crossmember (6.0L, 6.6L, and 8.1L Engines)
    GM788013Courtesy of GENERAL MOTORS CORP.
  12. Install the transmission support crossmember.
  13. Install the transmission support crossmember bolts.

    Tighten:  Tighten the bolts to 95 N.m (70 lb ft).

    14. Fig 7: Identifying Transmission Mount Nuts
    GM647997Courtesy of GENERAL MOTORS CORP.
  14. Lower the transmission onto the transmission support.
  15. Install the transmission mount to transmission support nuts.

    Tighten:  Tighten the nuts to 40 N.m (30 lb ft).

  16. Remove the support from the transmission.
  17. Lower the vehicle.
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