Exhaust Y-Pipe - Dual Catalytic Converter: Removal

WARNING: This page is about a different car, the 2012 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles

NOTE: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger bracket during vehicle operation.

NOTE: The exhaust Y-pipe dual catalytic converter is a 2-piece assembly. The RH and LH converters can be serviced separately as needed.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, REFER to JACKING & LIFTING .
3.5L Gasoline Turbocharged Direct Injection (GTDI)
Disconnect the LH Heated Oxygen Sensor (HO2S) pushpin and electrical connector.
All vehicles
If equipped, release the 4 fasteners and remove the splash shield.

Fig 1: Locating Fasteners And Splash Shield
Courtesy of FORD MOTOR CO.

3.5L GTDI
Disconnect the RH HO2S pushpin and electrical connector.
3.7L, 5.0L and 6.2L
Disconnect the 2 HO2S pushpins and electrical connectors.
All vehicles
Disconnect the 2 Catalyst Monitor Sensor (CMS) electrical connectors.
Loosen the RH catalytic converter-to-LH catalytic converter Torca® clamp.

Fig 2: Locating Catalytic Converter Torca® Clamp
Courtesy of FORD MOTOR CO.
Remove and discard the 2 LH catalytic converter-to-exhaust manifold or turbocharger nuts.

Fig 3: Locating LH Catalytic Converter-To-Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
Remove the LH catalytic converter from the vehicle.
Four-Wheel Drive (4WD) vehicles
If equipped, remove the 4 bolts and the transfer case skid plate.

Fig 4: Locating Skid Plate Bolts
Courtesy of FORD MOTOR CO.

All vehicles
Using an appropriate tool, support the transmission.

NOTE: LH side shown in illustration, RH similar.

Fig 5: Locating Heat Shield Bolts And Transmission Crossmember

Courtesy of FORD MOTOR CO.

Remove the 2 heat shield bolts from the transmission crossmember.
Remove the 2 transmission insulator and retainer/exhaust support bracket assembly nuts.
Remove the 4 transmission crossmember nuts, the 4 bolts and remove the transmission crossmember from the vehicle.
Remove the LH isolator cap from the transmission insulator and retainer/exhaust support bracket assembly.

Fig 6: Locating LH Isolator Cap And Bolt
Courtesy of FORD MOTOR CO.

4WD vehicles
Remove the 4 transmission insulator and retainer/exhaust support bracket assembly bolts and remove the transmission insulator and retainer/exhaust support bracket assembly from the vehicle.

Fig 7: Locating Bolts And Transmission Mounting Bracket
Courtesy of FORD MOTOR CO.

2-Wheel Drive (2WD) vehicles
Remove the 3 transmission insulator and retainer/exhaust support bracket assembly bolts and remove the transmission insulator and retainer/exhaust support bracket assembly from the vehicle.

Fig 8: Locating Transmission Insulator And Retainer/Exhaust Support Bracket Assembly Bolts
Courtesy of FORD MOTOR CO.

3.5L GTDI and 3.7L vehicles

NOTE: Do not excessively bend, twist or allow the exhaust intermediate pipe to hang from the flexible pipe or damage to the muffler and tailpipe may occur.

Support the exhaust intermediate pipe with a jackstand.
All vehicles
Remove the 2 RH catalytic converter-to-exhaust intermediate pipe bolts.
With help of an assistant, remove the 2 nuts on the RH catalytic converter-to-exhaust manifold or turbocharger joint and remove the RH catalytic converter from the vehicle.
- Discard the nuts.

Fig 9: Locating Lower And Upper Catalytic Converter-To-Exhaust Manifold Nuts RH

Courtesy of FORD MOTOR CO.