Exhaust - Y-Pipe Cracks at Bracket
Article No02-21-8
10/28/02
EXHAUST - EXHAUST SYSTEM Y-PIPE CRACK AT
THE NOISE VIBRATION HARNESS (NVH) BRACKET
FORD:
1997-1999 TAURUS
MERCURY:
1997-1999 SABLE
Article 02-18-3 is being republished in its entirety to update the Warranty Coverage.
ISSUE
On some 1997-1999 Taurus/Sable vehicles equipped with a 3.0L 2V/4V/FFV engine, there is a potential that the exhaust system Y-pipe may fracture at the Noise Vibration Harness (NVH) bracket, resulting in an exhaust system noise. The Y-pipe cracking is due to a combination of thermal expansion and contraction stress concentrations at the NVH bracket.
ACTION
A new more durable NVH bracket and repair procedure is now available for service instead of replacing the complete Catalyst assembly to repair the crack. Refer to the following Service Procedure and install the new NVH bracket.
SERVICE PROCEDURE
Inspect and verify the crack condition (Figure 1).
Remove the Exhaust System as per Section 09-00 of the Workshop Manual.
Clean the area of the crack with a wire brush. Repair the crack by welding it.
Please note the exhaust system is made of # 409 stainless steel and should be welded with similar material, (stainless), to insure maximum service life. Failure to use stainless weld material will cause premature corrosion of the welded area of this service repair.
Locate the new bracket, (XF1Z-2L320-AA), at 2.2 inches (56 mm) from the center of the HO2S boss, (Figure 2). Clean the areas of the exhaust pipe at the bracket contact area with a wire brush. Locate and secure the new bracket at 2.2 inches (56 mm) from the center of the H025 boss, (Figure 2).
Some Y-pipe assemblies have a grass shield which will require the bracket to be slipped between (Figure 3).
Tack weld the new bracket on both ends. Remove securing clamps and verify the bracket is correctly located (Figure 2).
Weld both ends of the bracket completely (Figure 4).
Cut a section approximately 1/2 inch (13 mm) wide, from the original NVH bracket (Figure 5).
Install exhaust as per Section 09-00 of the Workshop Manual.
Visually inspect the new bracket for clearance (Figure 6).
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 02-18-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
022108A Install NVH Bracket 1.0 Hr.
(Includes Time To Remove
And Install Catalytic
Converter) 3.0L MFI, 3.0L
DOHC And 3.0L FFV
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