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Exhaust System Alignment

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
    2. NOTE: LH side shown, RH side similar.
  2. If equipped, remove the transfer case skid plate.
    3. Fig 1: Transfer Case Skid Plate Bolts
    GF0022975Courtesy of FORD MOTOR CO.
  3. Loosen all exhaust component fasteners from the exhaust manifolds to the muffler inlet pipe except the RH catalytic converter-to-LH catalytic converter clamp.
  4. Verify that the RH catalytic converter-to-LH catalytic converter and tailpipe clamps are secure and pipes are fully inserted.
    5. NOTE: Make sure the exhaust isolators are not torn, damaged or binding.
  5. Beginning at the front of the vehicle, align the exhaust system to establish the maximum clearance to surrounding components. Make sure that all slip fit pipes are pushed all the way into the preceding pipe and the notches are correctly lined up with the tabs.
  6. Tighten the RH catalytic converter-to-exhaust manifold nuts in the following sequence:
    1. Tighten the RH upper catalytic converter-to-exhaust manifold nut.
      • Tighten to 40 Nm (30 lb-ft).
    2. Tighten the RH lower catalytic converter-to-exhaust manifold nut.
      • Tighten to 40 Nm (30 lb-ft).
    7. Fig 2: Locating Catalytic Converter Nuts
    GF0022976Courtesy of FORD MOTOR CO.
  7. Tighten the exhaust and transmission mounting bracket cap bolt.
    • Tighten to 35 Nm (26 lb-ft).
    8. Fig 3: Exhaust And Transmission Mounting Bracket Cap Bolt
    GF0022977Courtesy of FORD MOTOR CO.
    NOTE: A new RH catalytic converter-to-LH catalytic converter clamp must be installed whenever the clamp is loosened.
    NOTE: Make sure the new RH catalytic converter-to-LH catalytic converter clamp is positioned with the clamp bolt facing the front of the vehicle.
  8. If loosened, tighten the RH catalytic converter-to-LH catalytic converter clamp.
    • Tighten to 55 Nm (41 lb-ft).
    9. Fig 4: Right Catalytic Converter-To-Left Catalytic Converter Clamp
    GF0022978Courtesy of FORD MOTOR CO.
  9. Tighten the LH catalytic converter-to-exhaust manifold nuts in the following sequence:
    1. Snug the LH inner catalytic converter-to-exhaust manifold nut.
    2. Tighten the LH outer catalytic converter-to-exhaust manifold nut.
      • Tighten to 40 Nm (30 lb-ft).
    3. Tighten the LH inner catalytic converter-to-exhaust manifold nut.
      • Tighten to 40 Nm (30 lb-ft).
    10. Fig 5: Locating Catalytic Converter-To-Exhaust Manifold Nuts
    GF0022979Courtesy of FORD MOTOR CO.
  10. Tighten the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts in the following sequence:
    1. Snug the outer exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt.
    2. Tighten the inner exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt.
      • Tighten to 48 Nm (35 lb-ft).
    3. Tighten the outer exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt.
      • Tighten to 48 Nm (35 lb-ft).
  11. Start the engine and check the exhaust system for leaks.
    12. NOTE: LH side shown, RH side similar.
  12. If equipped, install the transfer case skid plate.
    • Tighten to 25 Nm (18 lb-ft).
    13. Fig 6: Transfer Case Skid Plate Bolts
    GF0022975Courtesy of FORD MOTOR CO.
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