Exhaust Pipe: Service and Repair
Exhaust Y-Pipe - Dual Catalytic ConverterExhaust System - Exploded View (Expedition and Navigator Part 1):
Exhaust System - Exploded View (Expedition and Navigator Part 2):
Exhaust System - Exploded View (Expedition EL and Navigator L Part 1):
Exhaust System - Exploded View (Expedition EL and Navigator L Part 2):
Material:
Removal
CAUTION: Do not use oil or grease-based lubricants on isolators as they deteriorate the rubber.
NOTE: The exhaust Y-pipe dual catalytic converter is a 2-piece assembly. The RH and LH converters can be serviced separately as needed.
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
Four wheel drive (4WD) vehicles
2. NOTE: LH side shown, RH side similar.
If equipped, remove the transfer case skid plate.
All vehicles
3. Disconnect the heated oxygen and catalyst monitor sensors electrical connectors.
4. Using a suitable jack, support the transmission.
5. Remove the LH heat shield bolt and LH heat shield and evaporative emissions (EVAP) canister assembly bolt.
6. Remove the RH heat shield bolt.
7. Remove the transmission mount nuts.
8. Remove the 4 crossmember bolts and the crossmember.
9. Loosen the exhaust and transmission mounting bracket cap bolt.
Rear wheel drive (RWD) vehicles
10. Remove the 3 bolts and then slide off the exhaust and transmission mounting bracket from the exhaust Y-pipe dual catalytic converter.
4WD vehicles
11. NOTE: On 4WD vehicles, the exhaust and transmission mounting bracket will not slide off the exhaust Y-pipe dual catalytic converter until the exhaust Y-pipe dual catalytic converter is removed from the vehicle.
NOTE: RH side shown, LH side similar.
Remove the 4 bolts from the exhaust and transmission mounting bracket.
All vehicles
12. Remove the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts.
13. NOTE: LH catalytic converter-to-exhaust manifold nuts shown, RH similar.
Remove and discard the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts.
14. NOTE: Use caution removing the exhaust Y-pipe dual catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs.
Remove the exhaust Y-pipe dual catalytic converter from the vehicle.
4WD vehicles
15. If necessary, remove the exhaust and transmission mounting bracket from the exhaust Y-pipe dual catalytic converter.
All vehicles
16. NOTE: A new RH catalytic converter-to-LH catalytic converter clamp must be installed whenever the clamp is loosened.
If necessary, loosen the RH catalytic converter-to-LH catalytic converter clamp.
17. If necessary, separate the RH catalytic converter from the LH catalytic converter.
18. If the RH catalytic converter-to-LH catalytic converter clamp is loosened, grind the spot weld and remove the RH catalytic converter-to-LH catalytic converter clamp. Clean the uneven surface area.
Installation
All vehicles
CAUTION: Do not tighten the fasteners until all components are assembled and aligned, making sure to tighten all fasteners beginning at the front of the vehicle. For additional information, refer to Exhaust System Alignment.
NOTE: Clean the mating surfaces of the exhaust manifold outlet flare and the exhaust Y-pipe dual catalytic converter inlet flares.
Also clean the mating surfaces of the exhaust Y-pipe dual catalytic converter-to-muffler assembly.
Make sure not to damage the exhaust manifold outlet flares, the exhaust Y-pipe-dual catalytic converter inlet flares or the studs.
NOTE: Always install new fasteners and RH catalytic converter-to-LH catalytic converter clamp.
1. NOTE: Make sure to apply anti-seize lubricant to the threads of the sensors before installation.
If removed, install the heated oxygen and the catalyst monitor sensors.
^ Tighten to 40 Nm (30 ft. lbs.)
2. If necessary, position a new RH catalytic converter-to-LH catalytic converter clamp with the clamp bolt facing the front of the vehicle.
3. If separated, install RH catalytic converter to the LH catalytic converter.
4WD vehicles
4. If removed, install the exhaust and transmission mounting bracket to the exhaust Y-pipe dual catalytic converter.
All vehicles
5. NOTE: Use caution installing the Y-pipe dual catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs.
Position the exhaust Y-pipe dual catalytic converter into the vehicle.
6. NOTE: LH catalytic converter-to-exhaust manifold nuts shown, RH similar.
Loosely install the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts.
4WD vehicles
7. NOTE: RH side shown, LH side similar.
Install the 4 exhaust and transmission mounting bracket-to-transmission bolts.
^ Tighten to 90 Nm (66 ft. lbs.)
RWD vehicles
8. Slide on the exhaust and transmission mounting bracket to the exhaust Y-pipe dual catalytic converter and install the 3 exhaust and transmission mounting bracket-to-transmission bolts.
^ Tighten to 90 Nm (66 ft. lbs.)
All vehicles
9. Install the 4 crossmember bolts and the crossmember.
^ Tighten to 90 Nm (66 ft. lbs.)
10. Install the exhaust and transmission mounting bracket nuts.
^ Tighten to 103 Nm (76 ft. lbs.)
11. Install the RH heat shield bolt.
^ Tighten to 20 Nm (15 ft. lbs.)
12. Install the LH heat shield bolt and LH heat shield and evaporative emissions (EVAP) canister assembly bolt.
^ Tighten to 20 Nm (15 ft. lbs.)
13. Loosely install the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts.
14. Connect the heated oxygen and catalyst monitor sensor electrical connectors.
15. Align the exhaust system.
4WD vehicles
16. NOTE: LH side shown, RH side similar.
If equipped, install the transfer case skid plate.
^ Tighten to 25 Nm (18 ft. lbs.)