We got most of the exhaust put together.
It's amazing how much larger in diameter the 5.3 exhaust is over the old 5.7.
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In California, when swapping a newer engine into an older vehicle, all of the smog equipment from the newer engine has to remain intact. The catalytic converters have to be mounted within 3 inches from their original location.
So far it's been pretty easy.
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We didn't want anything to hang lower than the bottom of the frame. The passenger side converter was OK, but the drivers side needed to be moved up and rotated just a little.
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The crossover tube on the 2002 exhaust ran under the transmission. For maintenance purposes I wanted to move the crossover further back. I bought a 90 degree section at Napa and along with a short piece of straight pipe, now the exhaust crosses over to the other side just under the tail section of the transmission.
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To help get the exhaust on and off we found these nice couplers at an exhaust shop here in San Diego.
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The joints are sealed with large donuts.
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I've had this Magnaflow muffler hanging out in my garage for a few years. Hopefully it sounds OK. The old exhaust I was running with the 5.7 was a true dual exhaust with Flowmaster mufflers. It sounded pretty when the 5.7 was healthy.
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I'm not sure what I am going to do about the tailpipe. With the Tahoe sitting so low it will be difficult to fit a 3" pipe up and over the axle. I will probably just go under the axle like this old Camaro.
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