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Catalytic Converter: Removal

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Do not use oil or grease-based lubricants on the isolators. They may cause deterioration of the rubber.
CAUTION: Oil or grease-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, clamps and coupling with the same part numbers as the originals. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.

    All engines 

  1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Remove the transfer case skid plate if equipped.
    Fig 1: Removing Transfer Case Skid Plate
    G03965004Courtesy of FORD MOTOR CO.
  3. Loosen the muffler-to-extension pipe exhaust clamp.
  4. Disengage the muffler from the 3 isolators and remove the muffler.
  5. Loosen the extension pipe-to-Y-pipe exhaust coupler.
  6. Remove and discard the extension pipe, the clamp and the extension pipe-to-Y-pipe exhaust coupler.
  7. Grind the spot weld, then remove and discard the LH catalytic converter-to-Y-pipe exhaust clamp.
  8. Disconnect the 2 catalyst monitor sensors electrical connectors.

    9. 4.6L and 5.4L engines 

  9. Disconnect the 2 heated oxygen sensors (HO2S) electrical connectors.

    10. All engines 

  10. If installing a new converter, use the special tool and remove the 2 catalyst monitor sensors and the 2 HO2S (if equipped).
    Fig 2: Using Special Tool And Removing Catalyst Monitor Sensors And HO2S
    G03965027Courtesy of FORD MOTOR CO.
  11. Using a jackstand, support the catalytic converters.
  12. Remove the 2 catalytic converter hanger bracket bolts.
  13. Remove and discard the 4 catalytic converter-to-manifold nuts.

    14. 4x4 vehicles 

  14. Index-mark the front driveshaft flange and the driveshaft yoke.
    Fig 3: Index-Marking Front Driveshaft Flange And Driveshaft Yoke
    G03928216Courtesy of FORD MOTOR CO.
  15. Remove the 4 driveshaft yoke bolts.
    Fig 4: Removing Driveshaft Yoke Bolts
    G03912443Courtesy of FORD MOTOR CO.
    16. CAUTION: The driveshaft flange fits tightly on the front axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange.
    Fig 5: Disconnecting Driveshaft Flange Yoke From Pinion Flange
    G03878446Courtesy of FORD MOTOR CO.
  16. Using a suitable tool as shown, disconnect the driveshaft from the flange.
  17. Position the driveshaft aside and support with mechanic's wire.

    18. All vehicles 

  18. Remove the LH exhaust shield bolt.
    Fig 6: Identifying LH Exhaust Shield Bolt
    G03964377Courtesy of FORD MOTOR CO.
    19. CAUTION: Do not damage the manifold outlet flare, the converter inlet flare or the studs.
  19. Support the LH catalytic converter near the rear outlet, then remove the catalytic converter.
  20. Remove the RH exhaust shield bolt.
    Fig 7: Locating RH Exhaust Shield Bolt
    G03929683Courtesy of FORD MOTOR CO.
    21. CAUTION: Do not damage the manifold outlet flare, the converter inlet flare or the studs.
  21. Support the RH catalytic converter near the rear outlet, then remove the catalytic converter.
  22. If necessary, remove the exhaust hanger bracket bolts.
  23. If necessary, remove the exhaust hanger brackets.
  24. If necessary, remove the catalytic converter isolator hanger bracket.
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