Removal and Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .

NOTE: 4.6L engine shown; 5.4L engine similar.

Fig 1: Identifying Three-Way Catalytic Converter To Exhaust Manifold Nuts

Courtesy of FORD MOTOR CO.

Remove the four exhaust Y-pipe-to-exhaust manifold nuts.

NOTE: It may be necessary to raise the exhaust Y-pipe for additional clearance when removing the exhaust manifold from the vehicle.

Fig 2: Removing Exhaust Manifold Nuts

Courtesy of FORD MOTOR CO.

Remove the eight nuts and the exhaust manifold.
Remove and discard the exhaust manifold gasket.

Fig 3: Removing Exhaust Manifold Gasket
Courtesy of FORD MOTOR CO.
Clean and inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
To install, reverse the removal procedure.
- Tighten the exhaust manifold nuts in the sequence shown in Fig 4.
  
  Fig 4: Identifying Tightening Sequence Of RH Exhaust Manifold Bolts
  Courtesy of FORD MOTOR CO.