Exhaust System Alignment

All engines 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING article.
2. Loosen all fasteners joining the exhaust system components.
3. Beginning at the front of the vehicle, align the exhaust system to establish the maximum clearance.

   Vehicles with 2.3L engine 

4. Position the exhaust downpipe to the exhaust manifold and loosely tighten the exhaust downpipe-to-exhaust manifold nuts to stiffen the joint.
   Fig 1: Locating Exhaust Downpipe-To-Exhaust Manifold Nuts

   Courtesy of FORD MOTOR CO.

   Vehicles with 4.0L engine 

NOTE: RH side shown in illustration, LH side similar.
Fig 2: Locating Exhaust Y-Pipe Assembly-To-Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
5. Position the exhaust Y-pipe assembly to the exhaust manifold and loosely tighten the exhaust Y-pipe assembly-to-exhaust manifold nuts to stiffen the joint.

   All engines 

6. Confirm the exhaust isolators are at zero load and hanging without any twist or binding.

   Vehicles with 2.3L engine 

7. Tighten the exhaust downpipe-to-exhaust manifold nuts.
   • Tighten to 40 Nm (30 lb-ft).
     Fig 3: Locating Exhaust Downpipe-To-Exhaust Manifold Nuts

     Courtesy of FORD MOTOR CO.

   Vehicles with 4.0L engine 

NOTE: RH side shown in illustration, LH side similar.
8. Tighten the exhaust Y-pipe assembly-to-exhaust manifold nuts.
   • Tighten to 40 Nm (30 lb-ft).
     Fig 4: Locating Exhaust Y-Pipe Assembly-To-Exhaust Manifold Nuts

     Courtesy of FORD MOTOR CO.

   All engines 

9. Confirm the exhaust isolators are at zero load and hanging without any twist or binding.

   Vehicles with 4.0L engine 

10. Tighten the LH side of the exhaust Y-pipe-to-RH side of exhaust Y-pipe nuts.
    • Tighten to 40 Nm (30 lb-ft).
11. Confirm the exhaust isolators are at zero load and hanging without any twist or binding.

    Vehicles with 2.3L engine 

12. Tighten the exhaust downpipe-to-muffler and tail pipe assembly bolts.
    • Tighten to 40 Nm (30 lb-ft).

    Vehicles with 4.0L engine 

13. Tighten the RH side of the exhaust Y-pipe-to-muffler and tail pipe assembly bolts.
    • Tighten to 40 Nm (30 lb-ft).

    All engines 

14. Confirm the exhaust isolators are at zero load and hanging without any twist or binding.
15. Start the engine and check the exhaust system for leaks.