Removal and Installation

WARNING: This page is about a different car, the 2004 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.

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 three-way catalytic converter. The temperature of the three-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 hanger isolator 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.

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

NOTE: Remove the brace when removing only the muffler.

Fig 1: Removing Bolts And Brace

Courtesy of FORD MOTOR CO.

Remove the bolts and the brace.
Remove the parts in the order indicated in the following illustration and table.

Fig 2: Removing Parts Muffler
Courtesy of FORD MOTOR CO.
To install, reverse the removal procedure.
Check and, if necessary, align the exhaust system.

Item 3: Exhaust Hanger Bracket Removal Note

Remove the exhaust hanger bracket and the exhaust hanger isolator as an assembly.

Item 4: Exhaust Hanger Isolator Removal Note

Inspect the isolator for wear or damage, install a new isolator as necessary.

Item 8: Converter Assembly Removal 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.

Item 9: Catalyst Monitor Sensor Removal Note

Using the special tool, remove the catalyst monitor sensors.

Fig 3: Removing Catalyst Monitor Sensors Using Special Tool
Courtesy of FORD MOTOR CO.

Item 10: Heated Oxygen Sensor Removal Note

Using the special tool, remove the heated oxygen sensors.

Fig 4: Removing Heated Oxygen Sensors Using Special Tool
Courtesy of FORD MOTOR CO.

Item 10: Heated Oxygen Sensor Installation Note

Apply anti-seize to the threads of the sensors before installation. Using the special tool, install the sensor.

Item 9: Catalyst Monitor Sensor Installation Note

Apply anti-seize lubricant to the threads of the sensors before installation. Using the special tool, install the sensor.

Item 8: Converter Assembly Installation Note

Clean the mating surfaces of the manifold outlet flare and the catalytic converter inlet flare. Support the catalytic converter near the rear outlet. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs. To correctly seat the converter, alternately tighten the exhaust manifold-to-catalytic converter nuts to specification.