Removal and Installation

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. 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 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.

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.

NOTE: Front catalytic converter shown, rear similar.

Remove and discard the 2 upper catalytic converter-to-exhaust manifold bolts and gasket for the front or rear catalytic converter.
- To install, install a new gasket and tighten to 40 Nm (30 lb-ft).
  
  Fig 1: Locating Catalytic Converter Bolts
  Courtesy of FORD MOTOR CO.
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
If removing the front catalytic converter, remove the bracket bolt.
- To install, tighten to 40 Nm (30 lb-ft).
  
  Fig 2: Removing Front Catalytic Converter Bracket Bolt
  Courtesy of FORD MOTOR CO.
Disconnect the catalyst monitor sensor electrical connector.

CAUTION: The catalytic converter nuts must be tightened as indicated to maintain correct exhaust system sealing and to prevent damage to the exhaust flanges.

Remove and discard the 2 lower catalytic converter nuts and remove the front or rear catalytic converter.
- To install, use a new gasket and alternately tighten the catalytic converter nuts while keeping the exhaust flanges parallel to one another. Tighten to 40 Nm (30 lb-ft).
  
  Fig 3: Locating Front Exhaust Pipe Nuts
  Courtesy of FORD MOTOR CO.
If removing the front catalytic converter, inspect the bracket clamp and install a new clamp if necessary.
- Tighten the clamp bolt to 40 Nm (30 lb-ft).

NOTE: Apply anti-seize lubricant to the catalyst monitor sensor threads before installation.

If installing a new catalytic converter, remove the catalyst monitor sensor.
- To install, tighten to 47 Nm (35 lb-ft).

NOTE: Clean the mating surfaces of the exhaust system connections.

To install, reverse the removal procedure.
- Always install new gaskets and exhaust fasteners.