Exhaust System Alignment

All vehicles

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 new gasket, fasteners, Torca® clamp and service coupler (if equipped) whenever an exhaust joint is loosened.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND 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 the 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(R) Clamp And Nut

Courtesy of FORD MOTOR CO.

Confirm that the exhaust isolators are at zero load.

4.0L Explorer Sport Trac

NOTE: The production muffler assembly is a one-piece design. The service muffler assembly is serviced with 2 pieces.

NOTE: If the muffler has not been removed from the vehicle, this muffler inlet pipe joint will not be present.

NOTE: If installing a service muffler kit, the coupling will be welded into position on the muffler inlet pipe.

NOTE: The factory muffler inlet pipe will not have an alignment nub.

If equipped, and not welded to the muffler inlet pipe, make sure that the service exhaust coupler is against the alignment nub and is positioned approximately at the 2 o'clock position facing the muffler. If the muffler inlet pipe does not have an alignment nub, center the exhaust coupler over the muffler inlet pipe joint and position it at approximately the 2 o'clock position facing the muffler.
- Tighten to 47 Nm (35 lb-ft).

Fig 2: Identifying Muffler Inlet Pipe Joint

Courtesy of FORD MOTOR CO.

4.6L Explorer Sport Trac

NOTE: The production muffler assembly is a one-piece design. The service muffler assembly is serviced with 2 pieces.

NOTE: If the muffler has not been removed from the vehicle, this muffler inlet pipe joint will not be present.

NOTE: If installing a service muffler kit, the coupling will be welded into position on the muffler inlet pipe.

NOTE: The factory muffler inlet pipe will not have an alignment nub.

If equipped, and not welded to the muffler inlet pipe, make sure that the service exhaust coupler is against the alignment nub and is positioned approximately at the 2 o'clock position facing the muffler. If the muffler inlet pipe does not have an alignment nub, center the exhaust coupler over the muffler inlet pipe joint and position it at approximately the 2 o'clock position facing the muffler.
- Tighten to 47 Nm (35 lb-ft).

Fig 3: Identifying Muffler Inlet Pipe Joint

Courtesy of FORD MOTOR CO.

Explorer Sport Trac

Confirm that the exhaust isolators are at zero load.

All vehicles

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 shown, LH similar.

Tighten the exhaust Y-pipe-dual catalytic converter-to-exhaust manifold nuts.
- Tighten to 40 Nm (30 lb-ft).

Fig 4: 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.