Catalytic Converter - FWD: Removal

NOTE: If the catalytic converter is not being replaced, the HO2S and the catalyst monitor sensor do not need to be removed from the catalytic converter. Disconnecting the electrical connectors is still necessary.

NOTE: Removal steps in this procedure may contain installation details.

With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
Remove the HO2S. Refer to: Heated Oxygen Sensor (HO2S) .
Remove the catalyst monitor sensor. Refer to: Catalyst Monitor Sensor .
Remove the EGR cooler inlet tube. Refer to: Exhaust Gas Recirculation (EGR) Cooler Inlet Tube .
Remove the bolts and the heat shield.
Torque: 97 lb.in (11 Nm)

Courtesy of FORD MOTOR COMPANY
Remove and discard the exhaust manifold nuts.

Courtesy of FORD MOTOR COMPANY
Remove the muffler and tailpipe. Refer to: Muffler and Tailpipe - Plug-In Hybrid Electric Vehicle (PHEV) . Refer to: Muffler and Tailpipe - Full Hybrid Electric Vehicle (FHEV) .
Remove the engine front undershield. Refer to: Engine Front Undershield .
Remove the catalytic converter support bracket bolts.
Torque: 18 lb.ft (25 Nm)

Courtesy of FORD MOTOR COMPANY
Using a holding device, hold the steering wheel in the straight-ahead position.

Courtesy of FORD MOTOR COMPANY
- Remove the bolt and discard.
- Position steering column shaft aside.
  Torque: 46 lb.ft (63 Nm)
Courtesy of FORD MOTOR COMPANY
If equipped.Remove the bolts and the shield.

Courtesy of FORD MOTOR COMPANY
1. Remove the screws.
2. Remove the push pins and the underbody deflector shield.
Courtesy of FORD MOTOR COMPANY
Remove the front bumper cover. Refer to: Front Bumper Cover .
Remove and discard the roll restrictor bracket bolt.

Courtesy of FORD MOTOR COMPANY
Remove the subframe support bracket bolts.

Courtesy of FORD MOTOR COMPANY
1. Remove and discard the rearward subframe bolts.
2. Remove the bolts and the subframe brackets.
Courtesy of FORD MOTOR COMPANY
On both sides, index-mark the subframe to the body.

Courtesy of FORD MOTOR COMPANY
On both sides, remove the front subframe bolts.

Courtesy of FORD MOTOR COMPANY
Support the subframe with a screw jack.Use the General Equipment: Wooden Block

Courtesy of FORD MOTOR COMPANY
On both sides, loosen the subframe bolts.

Courtesy of FORD MOTOR COMPANY
NOTE: Care must be taken when lowering the front subframe to ensure the front subframe mounting structure is not damaged.

NOTE: Lower the front subframe only enough to allow removal of the catalytic converter assembly.

Using a screw jack, lower the subframe.

Courtesy of FORD MOTOR COMPANY
Remove the lower bracket nut and the catalytic converter.

Courtesy of FORD MOTOR COMPANY
Remove and discard the gasket.

Courtesy of FORD MOTOR COMPANY
NOTE: The following step is only required if the components are being replaced with new items:

Remove the isolator bracket assembly.

Courtesy of FORD MOTOR COMPANY