Express 2500 V8-6.6L DSL Turbo VIN 2 (2007)
12. Remove the exhaust muffler nuts.
13. With the aid of an assistant, support the exhaust muffler.
14. With the aid of an assistant, slide the muffler rearward in order to remove the muffler from the catalytic converter.
15. Remove the insulators from the muffler hangers.
16. Remove the exhaust manifold pipe gasket, if necessary.
17. Remove the insulators from the frame hangers.
18. With the aid of an assistant, slide the muffler rearward in order to remove the muffler from the exhaust muffler pipe.
19. Remove the exhaust muffler gasket, if necessary.
20. Remove the insulators from the muffler hangers.
21. 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.
Installation Procedure
Important: Apply lubricant to the insulators to aid in installation.
1. Install the insulators to the muffler hangers.
2. Install a new exhaust muffler gasket.
3. With the aid of an assistant, slide the muffler forward in order to install the muffler to the exhaust muffler pipe.
4. Install the insulators to the frame hangers.
5. Install a new exhaust manifold pipe gasket.
6. With the aid of an assistant, slide the muffler forward in order to install the muffler to the catalytic converter.
7. Install the insulators to the frame hangers.
