Exhaust System Alignment

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .

NOTE: LH side shown in illustration, RH side similar.

Fig 1: Locating Bolts And Transfer Case Skid Plate

Courtesy of FORD MOTOR CO.

If equipped, remove the 6 bolts and transfer case skid plate.
Loosen all exhaust component fasteners from the exhaust manifolds to the muffler inlet pipe except the RH catalytic converter-to-LH catalytic converter Torca® clamp.
Verify that the RH catalytic converter-to-LH catalytic converter and tail pipe clamps are secure and pipes are fully inserted.

NOTE: Make sure the exhaust isolators are not torn, damaged or binding.

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.
Tighten the 2 RH catalytic converter-to-exhaust manifold nuts in the following sequence:
1. Tighten the RH lower catalytic converter-to-exhaust manifold nut.
  - Tighten to 40 Nm (30 lb-ft).
2. Tighten the RH upper catalytic converter-to-exhaust manifold nut.
  - Tighten to 40 Nm (30 lb-ft).
    
    Fig 2: Locating Lower/Upper Catalytic Converter-To-Exhaust Manifold Nuts RH
    Courtesy of FORD MOTOR CO.
Tighten the exhaust and transmission mounting bracket cap bolt.
- Tighten to 35 Nm (26 lb-ft).
  
  Fig 3: Locating Transmission Mounting Bracket Cap Bolt
  Courtesy of FORD MOTOR CO.
If loosened, tighten the RH catalytic converter-to-LH catalytic converter Torca® clamp.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 4: Locating Catalytic Converter Torca® Clamp
  Courtesy of FORD MOTOR CO.
Tighten the 2 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).
    
    Fig 5: Locating LH Catalytic Converter-To-Exhaust Manifold Nuts
    Courtesy of FORD MOTOR CO.
Tighten the 2 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 63 Nm (46 lb-ft).
3. Tighten the outer exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt.
  - Tighten to 63 Nm (46 lb-ft).
Start the engine and check the exhaust system for leaks.

NOTE: LH side shown in illustration, RH side similar.

Fig 6: Locating Bolts And Transfer Case Skid Plate

Courtesy of FORD MOTOR CO.

If equipped, install the transfer case skid plate and 6 bolts.
Tighten to 25 Nm (18 lb-ft).