Exhaust Crossover Pipe: Service and Repair
Exhaust Y-Pipe - Dual Catalytic ConverterExhaust System - Exploded View 4.0L Explorer Sport Trac (Part 1):
Exhaust System - Exploded View 4.0L Explorer Sport Trac (Part 2):
Exhaust System - Exploded View 4.6L Explorer Sport Trac (Part 1):
Exhaust System - Exploded View 4.6L Explorer Sport Trac (Part 2):
Exhaust System - Exploded View 4.0L Explorer/Mountaineer (Part 1):
Exhaust System - Exploded View 4.0L Explorer/Mountaineer (Part 2):
Exhaust System - Exploded View 4.6L Explorer/Mountaineer (Part 1):
Exhaust System - Exploded View 4.6L Explorer/Mountaineer (Part 2):
Removal
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. Use only water-based lubricants on the isolators.
NOTE: Exhaust fasteners are of a prevailing torque 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. For additional information, refer to Maintenance/Service and Repair.
2. Using a suitable jack, support the exhaust system.
3. Disconnect the heated oxygen sensor (HO2S) and the catalyst monitor sensors electrical connectors.
4. Remove the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts, nuts and gasket.
^ Discard the exhaust Y-pipe dual catalytic converter-to-muffler assembly nuts and gasket.
5. Remove the transmission support crossmember.
6. NOTE: RH side shown, LH similar.
Remove the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts.
^ Discard the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts.
7. Remove the exhaust Y-pipe dual catalytic converter.
Installation
1. NOTE: RH side shown, LH similar.
NOTE: Install new exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts.
NOTE: Do not fully torque the exhaust Y-pipe dual catalytic converter-to-exhaust manifold joint.
Position the exhaust Y-pipe dual catalytic converter to the exhaust manifold and loosely tighten all nuts to stiffen the joint enough to maintain position.
^ Tighten to 8 Nm (71 lb-in) and then add additional torque if needed to stiffen the joint.
2. NOTE: Install new exhaust Y-pipe dual catalytic converter-to-muffler assembly gasket and nuts.
Install the exhaust Y-pipe-dual catalytic converter-to-muffler assembly new gasket, bolts and new nuts.
^ Tighten to 40 Nm (30 lb-ft).
3. NOTE: RH shown, LH similar.
Tighten the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts.
^ Tighten to 40 Nm (30 lb-ft).
4. Install the transmission support crossmember.
5. Connect the HO2S and catalyst monitor sensors electrical connectors.
6. Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are not at zero load, then carry out the exhaust system alignment procedure.