RAM 2500 Truck 2WD V8-5.7L VIN D (2004)
Catalytic Converter: Service and Repair
CATALYTIC CONVERTER
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE FLAME NEAR THE
FUEL LINES.
1. Raise and support the vehicle.
2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
3. Remove the bolts from the crossover pipe to the catalytic converter connection.
4. Disconnect oxygen sensor wiring.
5. Loosen the nuts from the clamp that hold the catalytic converter to the exhaust pipe flange connection.
NOTE: Do not remove nut from T-Bolt. Only remove nut far enough, so that the T end can be removed from the clamp.
6. Remove the T-bolt end of the fastener from the clamp.
7. Spread the clamp, and remove the catalytic converter from the vehicle.
8. Discard the clamp.
NOTE: The catalytic converter to exhaust manifold clamp is not reusable. Always use a new clamp when reinstalling the catalytic converter.
INSPECTION
Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of overheating. If the converter has a heat
shield attached make sure it is not bent or loose.
If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate a damaged core.
INSTALLATION
NOTE: The catalytic converter to exhaust manifold clamp is not reusable. Always use a new clamp when reinstalling the catalytic converter.
1. Position the catalytic converter onto the exhaust pipe flange connection. Tighten the nuts to 28 Nm (250 in. lbs.) torque.
2. Install the muffler onto the catalytic converter until the alignment tab is inserted into the alignment slot.
3. Install the exhaust clamp at the muffler and catalytic converter connection. Tighten the clamp nuts to 47 Nm (35 ft. lbs.) torque.
4. Connect oxygen sensor wiring.
5. Lower the vehicle.
6. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed.
