Catalytic Converter

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

MATERIAL SPECIFICATION

Item	Specification
High Temperature Nickel Anti-Seize Lubricant XL-2 XL-2	ESE-M12A4-A

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 insulator 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 JACKING AND LIFTING .
Using a suitable jack, support the exhaust system.

NOTE: Make sure that the tab on the muffler outlet pipe is seated inside the notch on the extension pipe before tightening the exhaust clamp.

Remove the extension pipe-to-muffler assembly clamp nut.
- Detach the extension pipe isolator.
- To install, tighten to 48 Nm (35 lb-ft).
  
  Fig 1: Removing Extension Pipe Isolator
  Courtesy of FORD MOTOR CO.
Remove the muffler-to-catalytic converter assembly bolts, springs and flag nuts.
- Discard the flag nuts.
- Detach the muffler assembly isolators.
- To install, tighten to 40 Nm (30 lb-ft).

NOTE: When removing the catalytic converter assembly, the transmission crossmember must be removed.

Using a suitable jack, support the transmission.
Remove the heat shield bolts.
- To install, tighten to 20 Nm (15 lb-ft).
  
  Fig 2: Removing Heat Shield Bolts
  Courtesy of FORD MOTOR CO.
Remove the plastic shield from the RH side of the crossmember.
- To install, tighten to 9 Nm (80 lb-in).
  
  Fig 3: Removing Plastic Shield From RH Side Of Crossmember
  Courtesy of FORD MOTOR CO.
Remove the 4 upper crossmember bolts.
- To install, tighten to 70 Nm (52 lb-ft).
  
  Fig 4: Removing Upper Crossmember Bolts
  Courtesy of FORD MOTOR CO.
Remove the 4 lower crossmember bolts.
- To install, tighten to 70 Nm (52 lb-ft).
  
  Fig 5: Removing Lower Crossmember Bolts
  Courtesy of FORD MOTOR CO.
Remove the catalytic converter support isolator-to-transmission mount bolt.
- To install, tighten to 90 Nm (66 lb-ft).
Remove the transmission nuts and the transmission crossmember.

Fig 6: Removing Transmission Nuts And Transmission Crossmember
Courtesy of FORD MOTOR CO.
Detach the catalyst monitor sensor and heated oxygen sensor electrical connectors.

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 catalytic converter, alternately tighten the exhaust manifold-to-catalytic converter nuts to specification.

NOTE: If installing a new catalytic converter assembly, remove the catalyst monitor and heated oxygen sensors.

NOTE: Make sure to apply anti-seize compound to the threads of the sensors before installation.

Remove and discard the catalytic converter-to-exhaust manifold stud nuts.
- To install, tighten to 40 Nm (30 lb-ft).
To install, reverse the removal procedure.
Start the engine and check the exhaust system for leaks. If necessary, align the exhaust system. For additional information, refer to EXHAUST SYSTEM ALIGNMENT .