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Exhaust Y-Pipe

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: The normal operating temperature of the exhaust system is very high. Never attempt to service any part of the system until it has cooled. Be especially careful when working around the catalytic converter. The temperature of the catalytic converter rises to a high level after only a few minutes of engine operation.
CAUTION:
  • Do not use oil-based or grease-based lubricants on the isolators. They may cause deterioration to the rubber.
  • Oil-based or grease-based lubricants on the isolators may cause the exhaust hanger isolators to separate from the exhaust hanger bracket during vehicle operation.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
    2. 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.
  2. Remove and discard the 4 catalytic converter-to-Y-pipe nuts.
    • To install, alternately tighten the catalytic converter nuts while keeping the exhaust flanges parallel to one another.
    • To install, tighten to 40 N.m (30 lb-ft).
    3. CAUTION: Do not strike the catalytic converter or subject it to any force impacts (hammer blows). Doing so will damage the catalyst material.
  3. Remove and discard the 2 Y-pipe-to-underbody catalytic converter nuts.
    • To install, tighten to 40 N.m (30 lb-ft).
  4. Remove and discard the Y-pipe-to-underbody catalytic converter gasket.
    • To install, use a new gasket.
    Fig 1: Removing Y-Pipe-To-Underbody Catalytic Converter Gasket
    G04657683Courtesy of FORD MOTOR CO.
    5. NOTE: Inspect the isolator and install a new one if necessary.
  5. Disconnect the Y-pipe isolator and remove the Y-pipe.
  6. If necessary, remove the Y-pipe isolator bracket bolts, then remove the bracket.
    • To install, tighten to 30 N.m (22 lb-ft).
  7. Clean the mating surfaces of the exhaust system connections.

    To install, reverse the removal procedure.

    • Always install new gaskets and exhaust fasteners.
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