Catalytic Converter

SPECIAL TOOL(S) SPECIFICATIONS

Socket, Exhaust Gas Oxygen Sensor
303-476 (T94P-9472-A)

MATERIAL SPECIFICATIONS

Item	Specification
High Temperature Nickel Anti-Seize Lubricant XL-2	ESE-M12A4-A

WARNING: The normal operating temperature of the exhaust system is very high. Never attempt to repair or install any new part of the system until it has cooled. Be especially careful when working around the 3-way catalytic converter. The temperature of the 3-way catalytic converter rises to a high level after only a few minutes of engine operation.

CAUTION: Do not use oil or grease-based lubricants on the isolators. They may cause deterioration of the rubber.

CAUTION: Oil or greased-based lubricants on the isolators may cause the Exhaust isolator hanger to separate from the exhaust hanger bracket during vehicle operation.

NOTE: Exhaust fasteners are of a torque prevailing design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
Disconnect the 2 heated oxygen sensor (HO2S) and the 2 catalyst monitor sensor electrical connectors.

CAUTION: Do not excessively bend or twist the flex pipe.

Fig 1: Locating Flexible Pipe Support

Courtesy of FORD MOTOR CO.

Using a splint the length of the flex pipe and tie straps, support the flexible pipe.
Remove and discard the 2 catalytic converter-to-flex pipe bolts and gasket.
- Upon installation, install a new gasket and bolts and tighten to 40 Nm (30 lb-ft).
If unable to remove the flex pipe-to-catalytic converter bolts, carry out the following.
- Remove the head of the bolt by cutting or grinding.
- Remove the flex pipe assembly.
- Cut or grind the remaining portion of the bolt at the flange surface.
- Center punch the center of the remaining bolt at the flange surface.
- Drill out the bolt using a 10.5-mm (13/32-inch) drill bit.
- Clean the mating surfaces of the flex pipe and catalytic converter. Use a service bolt(s), N806408-S60, service flag nut(s) W705839-S441, and a new gasket during installation.

NOTE: Support the catalytic converter near the rear outlet. Use caution removing the catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs.

NOTE: If necessary, remove the damper.

Remove the lower catalytic converter bracket bolt.
- To install, tighten to 40 Nm (30 lb-ft).
  
  Fig 2: Locating Lower Catalytic Converter Bracket Bolt
  Courtesy of FORD MOTOR CO.
Remove the upper catalytic converter bracket bolt.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 3: Locating Upper Catalytic Converter Bracket Bolt
  Courtesy of FORD MOTOR CO.
Remove and discard the 4 catalytic converter-to-exhaust manifold nuts.
- Upon installation, install new nuts and
Remove the catalytic converter assembly.
- Clean the mating surfaces of the manifold outlet flare and the catalytic converter inlet flare.
If installing a new catalytic converter, remove the sensors.
- Apply High Temperature Nickel Anti-Seize Lubricant XL-2 meeting Ford specification ESE-M12A4-A or equivalent to the threads of the sensor(s) before installation. Using the special tool, install the sensor(s).
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 4: Identifying Special Oxygen Sensor Tool
  Courtesy of FORD MOTOR CO.

NOTE: Do not tighten the fasteners until all components are assembled. Make sure to tighten all fasteners beginning at the front of the vehicle.

To install, reverse the removal procedure.
- Check and, if necessary, align the exhaust system. For additional information, refer to EXHAUST SYSTEM ALIGNMENT .