Catalytic Converter: Service and Repair

REMOVAL

WARNING: The normal operating temperature of the exhaust system is very high. Never work around or attempt to service any part of the exhaust system until it has cooled. Use special care when working around the catalytic converter. These units heat to a high temperature after only a short period of operation.

1. Raise vehicle.
2. Install Exhaust Connector Holder T94T-6000-AH.
3. Support muffler and tailpipe assembly with a suitable jack stand and remove muffler and tailpipe assembly from the exhaust hanger insulators.
4. Remove exhaust clamp and remove the muffler and tailpipe from the exhaust system flex tube.

INSTALLATION

NOTE: When replacing the muffler and tailpipe assembly, the exhaust system flex tube or both, care must be taken to make sure that the exhaust system flex tube is inserted into the muffler to the proper depth. With the correct insertion of the exhaust system flex tube, the exhaust system flex will be neutralized.

1. Position the muffler and tailpipe assembly and slide it on the exhaust system flex tube.

NOTE: For ease of assembly, lubricate exhaust hanger insulators with Silicone Lubricant D7AZ-19553-AA or equivalent meeting Ford specification ESR-M13P4-A prior to installing muffler

2. Connect exhaust hanger insulators to rods welded to muffler and tailpipe assembly. Make sure exhaust hanger insulators hang straight up and down as illustrated to make sure the exhaust system flex tube is properly inserted into the muffler and tailpipe assembly.
3. Install and tighten exhaust clamp to 34-46 Nm (24-33 lb ft).
4. Remove Exhaust Connector Holder T94T-6000-AH.
5. Lower vehicle, start engine and check for leaks.