Exhaust System Alignment

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Loosen all fasteners joining the exhaust system components.
Beginning at the rear of the vehicle, the exhaust system should be aligned to establish the maximum clearance to its surrounding components. Make sure all fit pipes are pushed all the way into the preceding pipe and the pipe notches are fully seated and correctly lined up with the tabs.
Beginning at the rear of the vehicle, tighten the muffler-to-underbody catalytic converter or converter delete pipe (if equipped) to specification. For vehicles with wheelbases above 138 inches, tighten the muffler-to-extension pipe, followed by the underbody catalytic converter. For additional information, refer to SPECIFICATIONS . Tighten the Y-pipe-to-exhaust manifold nuts in the sequence shown in Fig 1:
1. Tighten the RH leg of the Y-pipe. Tighten the outboard exhaust manifold stud-to-Y-pipe nut to 20 Nm (15 lb-ft). Tighten the inboard exhaust manifold stud-to-Y-pipe nut to 40 Nm (30 lb-ft), then tighten the outboard exhaust manifold stud-to-Y-pipe nut to 40 Nm (30 lb-ft).
2. Tighten the LH leg of the Y-pipe. Tighten the outboard exhaust manifold stud-to-Y-pipe nut to 20 Nm (15 lb-ft). Tighten the inboard exhaust manifold stud-to-Y-pipe nut to 40 Nm (30 lb-ft), then tighten the outboard exhaust manifold stud-to-Y-pipe nut to 40 Nm (30 lb-ft).
  - Tighten the underbody catalytic converter-to-Y-pipe fasteners to specification. For additional information, refer to SPECIFICATIONS .
    
    Fig 1: Tightening RH Leg Of Y-Pipe
    Courtesy of FORD MOTOR CO.
Start the engine and check the exhaust system for leaks.