Catalytic Converter - Underbody: Removal

WARNING: This page is about a different car, the 2010 Mercury Mariner and 2010 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Do not use oil or grease-based lubricants on the insulators. They may cause deterioration of the rubber.

NOTE: Oil or grease-based lubricants on the insulators may cause the exhaust hanger insulator to separate from the exhaust hanger bracket during vehicle operation.

NOTE: The production catalytic converter and muffler assembly is a 1-piece construction. The service catalytic converter and muffler is a 2-piece construction.

NOTE: If replacement is not required, the production catalytic converter and muffler assembly can be removed and installed as one piece. It is only necessary to cut the production exhaust to enable the service information to be fitted. Before cutting any part of the exhaust system, check that the position of the cut is correct in comparison to the service information being installed.

All vehicles

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
2.5L vehicles
Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.
All vehicles

NOTE: Only use hand tools when removing or installing the spring nuts or damage may occur to the exhaust intermediate pipe/exhaust Y-pipe flange studs.

NOTE: When loosening the exhaust intermediate pipe/exhaust Y-pipe spring nuts, alternately loosen the nuts from side to side.

Remove and discard the two 10-mm exhaust catalytic converter-to-exhaust intermediate pipe/exhaust Y-pipe spring nuts.

NOTE: Only use hand tools when removing or installing the spring nuts or damage may occur to the resonator flange studs.

NOTE: When loosening the resonator spring nuts, alternately loosen the nuts from side to side.

Remove and discard the two 8-mm resonator-to-muffler spring nuts.

NOTE: Remove the gaskets by simultaneously pulling up and twisting the gasket on the pipe. Do not pry under the gasket or damage to the flange may occur.

Detach the 3 exhaust hangers and remove the catalytic converter and muffler assembly.
- Remove and discard the gaskets.
2.5L vehicles
Cut the exhaust system as indicated in illustration.

Fig 1: Identifying Exhaust System Cutting Dimension - 2.5L Vehicles
Courtesy of FORD MOTOR CO.

3.0L vehicles
Cut the exhaust system as indicated in illustration.

Fig 2: Identifying Exhaust System Cutting Dimension - 3.0L Vehicles
Courtesy of FORD MOTOR CO.

2.5L hybrid vehicles
Cut the exhaust system as indicated in illustration.

Fig 3: Identifying Exhaust System Cutting Dimension - 2.5L Hybrid Vehicles
Courtesy of FORD MOTOR CO.