Removal and Installation

WARNING: This page is about a different car, the 2006 Ford Pickup and 2006 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 & LIFTING .
Remove the air cleaner intake pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
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).

Four wheel drive (4WD) vehicles

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

All vehicles

Remove the 8 nuts, 8 studs and the exhaust manifold.
- Discard the 8 nuts and studs.
- To install, tighten the new studs to 12 Nm (9 lb-ft).
- To install, tighten the new nuts to 25 Nm (18 lb-ft) in the sequence shown.
  
  Fig 1: Identifying Exhaust Manifold Bolts
  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 ENGINE SYSTEM-GENERAL INFORMATION .
To install, reverse the removal procedure.