Exhaust Pipe: Service and Repair

Exhaust Intermediate Pipe - 5.4L

Removal and Installation

WARNING: The normal operating temperature of the exhaust system is very high. Never attempt to service any part of the system until it has cooled. Be especially careful when working around the catalytic converter. The temperature of the catalytic converter rises to a high level after only a few minutes of engine operation. Failure to follow these instructions may result in personal injury.

CAUTION: Do not use oil- or grease-based lubricants on the isolators. These lubricants may cause deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger bracket during vehicle operation.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Support the muffler and tailpipe assembly with a safety stand.
3. Release the exhaust intermediate pipe and (if equipped, the extension pipe) and the front muffler and tailpipe hanger isolators.
4. Loosen the exhaust intermediate pipe-to-catalytic converter Torca clamp nut and release the tension on the clamp.
^ To install, tighten to 40 Nm (30 ft. lbs.).
5. Remove the exhaust intermediate pipe and (if equipped, the extension pipe) and the muffler and tailpipe assembly from the catalytic converter.
6. Loosen the muffler and tailpipe assembly and (if equipped, the muffler inlet extension pipe-to-muffler inlet pipe Torca clamp(s) nut) and release the tension on the clamp(s).
^ To install, tighten to 40 Nm (30 ft. lbs.).
7. Remove the exhaust intermediate pipe and (if equipped, the extension pipe) from the muffler and tailpipe assembly.
8. If equipped, remove the exhaust intermediate pipe from the extension pipe.
9. To install, reverse the removal procedure.