Catalytic Converter: Service and Repair
Catalytic Converter
Special Tool(s)
Material
WARNING: The normal operating temperature of the exhaust system is very high. Never attempt to repair or install any new part of the system until it has cooled. Be especially careful when working around the 3-way catalytic converter. The temperature of the 3-way catalytic converter rises to a high level after only a few minutes of engine operation.
CAUTION: Do not use oil or grease-based lubricants on the isolators. They may cause deterioration of the rubber.
CAUTION: Oil or greased-based lubricants on the isolators may cause the Exhaust isolator hanger to separate from the exhaust hanger bracket during vehicle operation.
NOTE: Exhaust fasteners are of a torque prevailing design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Using a suitable jack, support the exhaust system.
3. CAUTION: Do not excessively bend or twist the flex pipe.
Using a splint the length of the flex pipe and tie straps, support the flexible pipe.
4. Remove the muffler-to-flex pipe clamp nuts.
^ To install, tighten to 47 Nm (35 ft. lbs.).
5. Remove the trackbar.
1. Remove the trackbar bolt.
2. Detach the trackbar from the body.
^ To install, tighten to 90 Nm (66 ft. lbs.).
6. Remove the Exhaust isolator hangers.
7. NOTE: It may be necessary to heat the muffler-to-exhaust system flex pipe joint to ease removal.
Detach the muffler assembly from the flex pipe, then remove the muffler assembly.
8. NOTE: Use a new gasket during installation.
Remove the flex pipe bolts, then remove the flex pipe.
9. If unable to remove the flex pipe-to-catalytic converter bolts, carry out the following.
^ Remove the head of the bolt by cutting or grinding.
^ Remove the flex pipe assembly.
^ Cut or grind the remaining portion of the bolt at the flange surface. Do not damage the gasket surfaces.
^ Center punch the center of the remaining bolt at the flange surface.
^ Drill out the bolt using a 10.5-mm (13/32-inch) drill bit.
^ Clean the mating surfaces of the flex pipe and catalytic converter. Use a service bolt(s), N806408-S60, service flag nut(s) W705839-S441, and a new gasket during installation.
10. Disconnect the heated oxygen and catalyst monitor sensor connectors.
11. NOTE: Support the catalytic converter near the rear outlet. Use caution removing the catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs.
NOTE: If necessary, remove the damper.
Disconnect the lower catalytic converter bracket.
^ To install, tighten to 40 Nm (30 ft. lbs.).
12. Disconnect the upper catalytic converter bracket.
^ To install, tighten to 40 Nm (30 ft. lbs.).
13. Remove and discard the catalytic converter-to-exhaust manifold nuts.
^ To install, tighten to 40 Nm (30 ft. lbs.).
14. Remove the catalytic converter assembly.
^ Clean the mating surfaces of the manifold outlet flare and the catalytic converter inlet flare.
15. If installing a new catalytic converter, remove the sensors.
^ Apply High Temperature Nickel Anti-Seize Lubricant XL-2 meeting Ford specification ESE-M12A4-A or equivalent to the threads of the sensor(s) before installation. Using the special tool, install the sensor(s).
^ To install, tighten to 40 Nm (30 ft. lbs.).
16. NOTE: Do not tighten the fasteners until all components are assembled. Make sure to tighten all fasteners beginning at the front of the vehicle.
To install, reverse the removal procedure.
17. Check and, if necessary, align the exhaust system.