Exhaust System Alignment

WARNING: The normal operating temperature of the exhaust system is very high. Never work around or attempt to repair any part of the exhaust system until it has cooled. Use special care when working around the catalytic converter. The catalytic converter heats to a high temperature after only a short period of engine operation. Failure to follow these instructions may result in personal injury.

CAUTION: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger bracket during vehicle operation. Use only water-based lubricants on the isolators.

NOTE: Exhaust fasteners are of a prevailing torque design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.

NOTE: Always install a new gasket, fasteners and Torca® clamp whenever an exhaust joint is loosened.

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.

NOTE: To install a new muffler assembly-to-tailpipe Torca® clamp, the tailpipe must be removed from the vehicle.

Install a new muffler assembly-to-tailpipe Torca® clamp. For additional information, refer to TAILPIPE .

NOTE: Do not fully torque the exhaust Y-pipe dual catalytic converter-to-exhaust manifold joint.

Position the exhaust Y-pipe dual catalytic converter-to-exhaust manifold and loosely tighten all nuts to stiffen the joint enough to maintain position.
- Tighten to 8 Nm (71 lb-in) and then add additional torque if needed to stiffen the joint.

NOTE: Make sure that the tab on the muffler assembly is seated inside the notch on the tailpipe before tightening the Torca® clamp.

Tighten the muffler assembly-to-tailpipe Torca® clamp.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 1: Locating Muffler Assembly-To-Tailpipe Torca® Clamp And Nut
  Courtesy of FORD MOTOR CO.
Confirm that the exhaust isolators are at zero load.
Tighten the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts.
- Tighten to 40 Nm (30 lb-ft).
Confirm that the exhaust isolators are at zero load.

NOTE: RH side shown, LH similar.

Tighten the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 2: Locating Exhaust Y-Pipe Dual Catalytic Converter-To-Exhaust Manifold Nuts
  Courtesy of FORD MOTOR CO.
Confirm that the exhaust isolators are at zero load.
Start the engine and check the exhaust system for leaks.