Exhaust System Alignment

All vehicles 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
2. Loosen the muffler-to-intermediate pipe clamp.
3. Loosen the exhaust coupler nuts. Do not tighten the coupler at this time.
4. Loosen the converter-to-manifold nuts. Do not tighten the nuts at this time.
5. Position an adjustable jackstand under the rear of the catalytic converter.
6. Make sure the exhaust system hanger rods are correctly inserted into all of the exhaust isolators.

Early build vehicles 

7. Using the jackstand, adjust the height of the catalytic converter until the converter hanger rods are centered in the exhaust isolators at the transmission crossmember.
Fig 1: Adjusting Height Of Catalytic Converter Until Hanger Rods Are Centered In Exhaust Isolators At Transmission Crossmember Using Jackstand
Courtesy of FORD MOTOR CO.

Late build vehicles 

NOTE: The exhaust system clearance must be checked on both the RH and LH side of the catalytic converter and both intermediate pipes (LH and RH).
8. Using the jackstand, adjust the height of the catalytic converter until:
   1. the clearance between the catalytic converter and the floor pan (at the transmission cross member position) is 30 mm (1.18 in).
   2. the clearance between the bottom of the intermediate pipe and the top of the lateral stiffener bar is 34 mm (1.34 in).
Fig 2: Adjusting Height Of Catalytic Converter Using Jackstand With Specifications
Courtesy of FORD MOTOR CO.

All vehicles 

9. Beginning at the front of the vehicle, align the exhaust system in the following sequence.
   1. Hand-tighten all the catalytic converter nuts.
   2. Alternately tighten, in 10 N.m (89 lb-in) increments, the upper catalytic converter-to-manifold nuts to 40 N.m (30 lb-ft).
      • LH upper.
      • RH upper.
   3. Alternately tighten, in 10 N.m (89 lb-in) increments, the lower catalytic converter-to-manifold nuts to 40 N.m (30 lb-ft).
      • LH lower.
      • RH lower.
   4. Verify the intermediate pipe button is fully seated to the bottom of the muffler inlet pipe notch.
      • Tighten the muffler-to-intermediate pipe clamp nuts to 48 N.m (35 lb-ft).
   NOTE: Make sure that the intermediate pipe is inserted into the coupler correctly. Correct installation is achieved when the rearmost end of the coupler terminates in the knurled region of the intermediate pipe.
   5. Slide coupler over catalyst pipe and engage the coupler clip completely over the converter button.
   6. Push the muffler forward. The back of the exhaust coupler should be in the crosshatched area on the intermediate pipe.
      • Alternately tighten, in 10 Nm (89 lb-in) increments, the intermediate pipe-to-converter assembly coupling(s) to 48 Nm (35 lb-ft).
Fig 3: Locating Crosshatched Area On Intermediate Pipe
Courtesy of FORD MOTOR CO.
10. Start the engine and check the exhaust system for leaks.