Dual Catalytic Converter Y-Pipe - AWD: Removal

WARNING: This page is about a different car, the 2024 Ford Transit-350 HD, 2024 Ford Transit-350, 2024 Ford Transit-250, and 2024 Ford Transit-150. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: If the dual catalytic converter Y-Pipe is not being replaced, the HO2S (heated oxygen sensor) and the catalyst monitor sensor do not need to be removed from the dual catalytic converter Y-Pipe. Disconnecting the electrical connectors is still necessary.

NOTE: This procedure is to remove and install the dual catalytic converter Y-pipe as an assembly. If the LH and RH catalytic converters need replacement, they must be replaced with a new dual catalytic converter Y-pipe assembly. If either the LH or RH catalytic converter need replaced individually, separate kits are available with instructions included for the repair.

Position vehicle on a hoist. Refer to: Jacking and Lifting - 3.5L Duratec (202kW/275PS)/3.5L EcoBoost (235kW/320PS) - Overview .
Remove the front subframe. Refer to: REMOVAL AND INSTALLATION
Remove the transmission support crossmember. Refer to: Transmission Support Crossmember .
Detach the retainer and disconnect the LH HO2S.

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Detach the retainer and disconnect the LH catalyst monitor sensors.

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Disconnect the RH HO2S.

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Remove the RH catalyst monitor sensor. Refer to: Catalyst Monitor Sensor .
Remove and discard the RH catalytic converter flange nuts.

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Remove and discard the LH catalytic converter flange nuts.

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NOTE: Make sure that the exhaust flexible pipe is not forcibly bent or twisted.

Use the General Equipment: Cable Ties

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Remove the exhaust flange bolts and detach the exhaust hanger isolator.

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NOTE: This step requires the aid of another technician.

Remove the bracket bolts and the dual catalytic converter / Y-pipe assembly.

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NOTE: This step is only required if you are replacing the adapter.

Remove and discard the bolts, remove the adapter.

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NOTE: This step is only required if you are replacing the adapter.

Remove and discard the RH gasket.

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Remove and discard the LH gasket.

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NOTE: This step is only required if you are replacing with new components.
- Remove the catalytic converter brace bracket.
- Apply penetrating oil to sensor, using the special tool remove the HO2S and the catalyst monitor sensors.Use Special Service Tool: 303-476 (T94P-9472-A) Socket, Exhaust Gas Oxygen Sensor.
  Material: Penetrating Fluid

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