Muffler and Tailpipe: Installation

NOTE: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause deterioration of the isolator. This can lead to separation of the isolators from the exhaust hanger bracket during vehicle operation.

NOTE: Clean the mating surfaces of the exhaust Y-pipe dual catalytic converter-to-muffler assembly.

NOTE: Check the exhaust hanger isolators for wear or damage, install new isolators, if necessary.

Install the muffler assembly into the vehicle and attach the isolators.
Install the 2 exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts and tighten in the following sequence:
1. Snug the outer exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt.
2. Tighten the inner exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt.
  - Tighten to 63 Nm (46 lb-ft).
3. Tighten the outer exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt.
  - Tighten to 63 Nm (46 lb-ft).
Install the tail pipe for Expedition models or the resonator for Navigator models and install the isolator and 2 bracket assembly bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 1: Locating Isolator And Bracket Assembly Bolts
  Courtesy of FORD MOTOR CO.
Tighten the tail pipe or resonator-to-muffler assembly Torca® clamp.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 2: Locating Tail Pipe Or Resonator-To-Muffler Assembly Torca® Clamp
  Courtesy of FORD MOTOR CO.
Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are not at zero load, then carry out the exhaust system alignment procedure. For additional information, refer to the EXHAUST SYSTEM ALIGNMENT in this information.

NOTE: LH side shown in the illustration, RH side similar.

If equipped, install the transfer case skid plate and 6 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 3: Locating Transfer Case Skid Plate Bolts
  Courtesy of FORD MOTOR CO.