Removal and Installation

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Raise and support the vehicle.
On 4x4 vehicles, remove the front wheel opening molding. For additional information, refer to FRONT END BODY PANELS .
Remove the front fender splash shield (16103). For additional information, refer to FRONT END BODY PANELS .

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

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

Courtesy of FORD MOTOR CO.

Remove the three-way catalytic converter to exhaust manifold nuts.
Remove the eight nuts and the exhaust manifold (9430).

Fig 2: Removing Exhaust Manifold
Courtesy of FORD MOTOR CO.
Remove and discard the exhaust manifold gasket (9448).

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.
Fig 4: Exhaust Manifold Nut Tightening Sequence
Courtesy of FORD MOTOR CO.