Exhaust Y-Pipe - Dual Catalytic Converter: Installation

All vehicles 

1. With the help of an assistant, position the RH catalytic converter into the vehicle and loosely install 2 new RH catalytic converter-to-exhaust manifold or turbocharger nuts.
   Fig 1: Locating Lower And Upper Catalytic Converter-To-Exhaust Manifold Nuts RH

   Courtesy of FORD MOTOR CO.
NOTE: If equipped, do not excessively bend, twist or allow the exhaust to hang from the flexible pipe or damage to the muffler and tailpipe may occur.
2. Loosely install the 2 RH catalytic converter-to-intermediate pipe bolts.

   2WD vehicles 

3. Install the transmission insulator and retainer/exhaust bracket assembly and 3 bolts.
   • Tighten to 90 Nm (66 lb-ft).
   Fig 2: Locating Bolts And Transmission Mounting Bracket From Exhaust Y-Pipe Dual Catalytic Converter

   Courtesy of FORD MOTOR CO.
4. Install the transmission crossmember, 4 bolts and 4 nuts.
   • Tighten to 90 Nm (66 lb-ft).
   Fig 3: Locating Transmission Crossmember Bolts

   Courtesy of FORD MOTOR CO.
5. Lower the transmission onto the transmission crossmember and install the 2 transmission insulator and retainer/exhaust support bracket assembly nuts.
   • Tighten to 103 Nm (76 lb-ft).
   Fig 4: Removing Rear Transmission Support Nuts

   Courtesy of FORD MOTOR CO.

   4WD vehicles 

6. Loosely install the transmission insulator and retainer/exhaust support bracket assembly and the 4 bolts.
   Fig 5: Locating Bolts And Transmission Mounting Bracket

   Courtesy of FORD MOTOR CO.
7. Position the transmission crossmember and loosely install the 2 transmission insulator and retainer/exhaust support bracket assembly nuts.
   Fig 6: Locating Transmission Insulator And Retainer Nuts

   Courtesy of FORD MOTOR CO.
8. Install the 4 transmission crossmember bolts and nuts.
   • Tighten the transmission insulator and retainer/exhaust support bracket assembly and 4 bolts to 90 Nm (66 lb-ft).
   • Tighten the transmission crossmember bolts and nuts to 90 Nm (66 lb-ft).
   • Tighten the 2 transmission insulator and retainer/exhaust support bracket assembly nuts to 103 Nm (75 lb-ft).
   Fig 7: Locating Transmission Support Crossmember Nuts And Bolts

   Courtesy of FORD MOTOR CO.

   All vehicles 

9. Loosely install the LH isolator cap and bolt onto the transmission insulator and retainer/exhaust support bracket assembly.
   Fig 8: Locating LH Isolator Cap And Bolt

   Courtesy of FORD MOTOR CO.
NOTE: LH side shown in illustration, RH similar.
Fig 9: Locating Heat Shield Bolts And Transmission Crossmember
Courtesy of FORD MOTOR CO.
10. Install the 2 heat shield bolts into the transmission crossmember.
    • Tighten to 15 Nm (133 lb-in).

    4WD vehicles 

11. If equipped, install the transfer case skid plate and 4 bolts.
    • Tighten to 24 Nm (18 lb-ft).
    Fig 10: Locating Skid Plate Bolts

    Courtesy of FORD MOTOR CO.

    All vehicles 

12. Slide the LH catalytic converter into the RH catalytic converter up to the stop on the LH catalytic converter and position the LH catalytic converter into place.
    Fig 11: Locating LH Catalytic Converter Into RH Catalytic Converter

    Courtesy of FORD MOTOR CO.
13. Loosely install the 2 new LH catalytic converter-to-exhaust manifold or turbocharger nuts.
    Fig 12: Locating LH Catalytic Converter-To-Exhaust Manifold Nuts

    Courtesy of FORD MOTOR CO.
14. Tighten the 2 new RH catalytic converter-to-exhaust manifold or turbocharger nuts in the following sequence.
    1. Tighten the RH lower catalytic converter-to-exhaust manifold or turbocharger nut to 40 Nm (30 lb-ft).
    2. Tighten the RH upper catalytic converter-to-exhaust manifold or turbocharger nut to 40 Nm (30 lb-ft).
    Fig 13: Locating Lower And Upper Catalytic Converter-To-Exhaust Manifold Nuts RH

    Courtesy of FORD MOTOR CO.
15. Tighten the LH isolator cap bolt.
    • Tighten to 55 Nm (41 lb-ft).
    Fig 14: Locating LH Isolator Cap Bolt

    Courtesy of FORD MOTOR CO.
16. Tighten the RH catalytic converter-to-LH catalytic converter Torca® clamp.
    • Tighten to 55 Nm (41 lb-ft).
    Fig 15: Locating Catalytic Converter Torca® Clamp

    Courtesy of FORD MOTOR CO.
17. Tighten the 2 new LH catalytic converter-to-exhaust manifold or turbocharger nuts in the following sequence.
    1. Snug the LH inner catalytic converter-to-exhaust manifold or turbocharger nut.
    2. Tighten the LH outer catalytic converter-to-exhaust manifold or turbocharger nut to 40 Nm (30 lb-ft).
    3. Tighten the LH inner catalytic converter-to-exhaust manifold or turbocharger nut to 40 Nm (30 lb-ft).
    Fig 16: Locating LH Catalytic Converter-To-Exhaust Manifold Nuts

    Courtesy of FORD MOTOR CO.
NOTE: If equipped, do not excessively bend, twist or allow the exhaust to hang from the flexible pipe or damage to the muffler and tailpipe may occur.
18. Tighten the exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolts in the following sequence.
    1. Snug the outer exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt.
    2. Tighten the inner exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt to 63 Nm (46 lb-ft).
    3. Tighten the outer exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt to 63 Nm (46 lb-ft).
19. Connect the 2 CMS electrical connectors.

    3.7L, 5.0L and 6.2L 

20. Connect the 2 HO2S pushpins and electrical connectors.

    3.5L GTDI 

21. Connect the RH HO2S pushpin and electrical connector.

    All vehicles 

22. If equipped, install the splash shield and the 4 fasteners.
    Fig 17: Locating Fasteners And Splash Shield

    Courtesy of FORD MOTOR CO.

    3.5L GTDI 

23. Connect the LH HO2S pushpin and electrical connector.

    All vehicles 

24. Start engine and check for exhaust leaks.