Exhaust System Alignment

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Loosen the muffler-to-intermediate pipe clamp.
Loosen the exhaust coupler nuts. Do not tighten the coupler at this time.
Loosen the converter-to-manifold nuts. Do not tighten the nuts at this time.
Position an adjustable jackstand under the catalytic converter Y-pipe/H-pipe.
Make sure the exhaust system hanger rods are correctly inserted into all of the muffler exhaust isolators.
Using the jackstand, adjust the height of the LH and RH catalytic converter until there is a 50 mm (1.96 in) clearance between the exhaust pipe and the floor pan (measuring just behind the heat shield).

Fig 1: Identifying Clearance Between Exhaust Pipe And Floor Pan
Courtesy of FORD MOTOR CO.
Beginning at the front of the vehicle, align the exhaust system in the following sequence.
1. Evenly tighten all 4 of the catalytic converter-to-exhaust manifold nuts (starting with the right lower, then the left lower, then the right upper, then the left upper) in 10 Nm (89 lb-in) increments until reaching the final torque of 45 Nm (35 lb-ft).
2. Verify the intermediate pipe button is fully seated to the bottom of the muffler inlet pipe notch.
  - Tighten the muffler-to-intermediate pipe exhaust clamp nuts to 48 Nm (35 lb-ft).
3. Slide coupler over catalyst pipe and engage the coupler clip completely over the converter button.
4. 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 2: Locating Coupler Over Catalyst Pipe
    Courtesy of FORD MOTOR CO.
Start the engine and check the exhaust system for leaks.