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Catalytic converter and muffler replacement questions

1045 Views 4 Replies 3 Participants Last post by  irateb
Hey All,

I have an '02 SE CC LB that has been throwing a P0420 for the past 4 - 5 years, and I'd been getting away with it in Georgia by resetting the ECU, driving 100 miles to the emissions testing place, and then the light would come back on around 102 miles. This method got worse with each year, and last year, I had to do the reset, use premium gas, and a couple rounds of intake cleaner before it worked. I had replaced all but one oxygen sensor a few years back (rear passenger, super stuck), but that didn't help the issue, so this year I decided to replace all the cats and the muffler. I went all Magnaflow. The drivers side was tough, but not really difficult and I've got those two cats and the muffler in place. The passenger side is starting to look impossible. I've got the two bolts from the rear cat to the Y pipe off, but only 2 of the 3 from the front cat to rear cat (still can't get that O2 sensor off, will probably just destroy it) and the manifold to front cat bolts are covered in a seemingly endless amount of heat shielding. My first question is, if you can remember doing it, what all had to be done to get the passenger side front cat out?

Second question is in regards to the Magnaflow muffler. The muffler looks like it was expecting two hangers, but my truck only has one. This muffler is a bit heavier than the OEM one. Should I get another hanger or will it be ok once I get everything bolted and tightened up?
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Thanks for the ideas. I fought with it some more and got all the bolts out, but it looks like I either have to disassemble some more or bust out the Sawzall to actually get it out. I'll do that tomorrow.
I've got the 4-cyl but thought I'd chime in on muffler question. I bought a Magnaflow cat-back for mine and the muffler had two hanger hooks. I looked in the service manual and thought it showed two hangers for the 6-cyl; just one for the 4. I figured they just used the same muffler for both. Anyway, my OCD wouldn't let me have a hanger hook just sitting there w/o being hooked to anything, so I paid $10-$15 for another hanger and bolts and, sure enough, there were a couple of threaded holes in the frame right where they needed to be. There was definitely less "wiggle" in the system with the second hanger connected. Anyway, just FWIW.

PS I got the parts from my local dealer.
Thanks! My OCD must be similar to yours. I have the 6 cyl, but for some reason, only one hanger is there. I do see the holes for the second hanger, so I will go ahead and order it.

And as a final post, I got the passenger side cats all out. I had to loosen the cross member that holds the transmission up. If anyone undertakes this, my biggest suggestion (other than removing the tires, which I think everyone suggests) is to remove as much of the heat shielding as possible before unbolting the cats. I got everything in, but I think I have a couple exhaust leaks. I'm a bit tired of messing with it, so I may take it to a shop to tighten/fix the leaks. The main thing is that so far, the SES light is still off when it was coming on within a few miles. Thanks again for the assistance!
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