Catalytic Converter: Removal

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 .
Remove the Heated Oxygen Sensor (HO2S). For additional information, refer to ELECTRONIC ENGINE CONTROLS .
Remove the 4 bolts and position aside the heat shield.

Fig 1: Locating Heat Shield Bolts
Courtesy of FORD MOTOR CO.
Remove and discard the 4 nuts and 1 bolt.

Fig 2: Locating Nuts And Bolt Of Catalytic Converter
Courtesy of FORD MOTOR CO.
Remove the RH halfshaft. For additional information, refer to Front Drive Halfshafts, Halfshaft - Exploded View in FRONT DRIVE HALFSHAFTS .
Remove the Catalyst Monitor Sensor (CMS). For additional information, refer to ELECTRONIC ENGINE CONTROLS .
Remove the 3 bolts and the halfshaft support bracket.

Fig 3: Locating Halfshaft Support Bracket Bolts
Courtesy of FORD MOTOR CO.
Remove the 4 bolts and the catalytic converter bracket.

Fig 4: Locating Catalytic Converter Bracket Bolts
Courtesy of FORD MOTOR CO.

NOTE: Do not forcibly bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe.

Fig 5: Supporting Exhaust Flexible Pipe With Support Wrap Or Suitable Splint

Courtesy of FORD MOTOR CO.

Using cable ties, support the exhaust flexible pipe with a support wrap or suitable splint.

NOTE: Do not forcibly bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe.

Fig 6: Locating Catalytic Converter-To-Muffler And Tailpipe Assembly Nuts

Courtesy of FORD MOTOR CO.

Detach the muffler and tailpipe assembly isolator and remove the 2 catalytic converter-to-muffler and tailpipe assembly nuts.
- Remove the catalytic converter assembly.
- Discard the 2 nuts and gaskets.