Removal and Installation

WARNING: This page is about a different car, the 2005 Ford Pickup and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
Remove the air cleaner intake pipe. For additional information, refer to AIR CLEANER INTAKE PIPE -- 5.4L (3V) .
Remove the 4 exhaust manifold-to-catalytic converter nuts.
- To install, tighten to 40 Nm (30 lb-ft).
Remove the 2 bolts and the exhaust manifold heat shield.
- To install, tighten to 10 Nm (89 lb-in).

4WD vehicles

Remove the front driveshaft. For additional information, refer to DRIVESHAFT .

All vehicles

Remove the 8 nuts and the exhaust manifold.
- To install, tighten to 25 Nm (18 lb-ft) in the sequence shown.
  
  Fig 1: Identifying Bolt Tightening/Loosening Sequence Of LH Exhaust Manifold
  Courtesy of FORD MOTOR CO.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

NOTE: Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.

Remove and discard the exhaust manifold gaskets. Clean the sealing surfaces with metal surface prep.
Inspect the exhaust manifold. For additional information, refer to EXHAUST MANIFOLD CLEANING AND INSPECTION .
To install, reverse the removal procedure.