Ford 7T4Z-9430-C Exhaust Manifold Assembly

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Disconnect the cable from the negative battery terminal. Disconnect the electrical connectors from the oxygen sensor and the catalytic converter monitor. Raise the front of the vehicle and support it securely on jackstands; on 2013 and later models, remove the lower engine splash shield and skid plate if equipped. From below, disconnect the crossover pipe. Remove the heat shield over the front exhaust manifold and the six nuts securing the exhaust manifold, then remove and discard the manifold gasket and the six nuts. Remove the exhaust manifold and, using a stud holding tool or a pair of nuts tightened together over a stud, extract the exhaust manifold studs and discard them. Use a scraper to remove all old gasket material and carbon deposits from the manifold and cylinder head mating surfaces, checking the manifold for warpage and resurfacing if necessary, while being cautious not to gouge the aluminum engine parts. Install new exhaust manifold studs with light oil on the threads, then place a new manifold gasket over the studs, followed by the manifold and new self-locking nuts. Tighten the nuts, starting with the center fasteners and working towards the ends, to the specified torque. For the rear exhaust manifold, disconnect the cable from the negative battery terminal, remove the EGR pipe from the exhaust manifold on 3.0L engines, and disconnect the connector to the rear bank oxygen sensor. On 3.5L engines, remove the rear-bank catalytic converter, noting that the converter heat shield on 3.0L AWD models requires the removal of the steering gear heat shield first. Remove the nuts from the exhaust manifold flange and separate the crossover pipe from the manifold, then remove the six exhaust manifold mounting nuts and the manifold from the engine, discarding the manifold gasket. Extract the exhaust manifold studs and discard them, then scrape all gasket material and carbon deposits from the mating surfaces, checking for warpage and resurfacing if necessary. Install new exhaust manifold studs with light oil on the threads, place a new manifold gasket over the studs, install the manifold and new self-locking nuts, and tighten the nuts starting with the center fasteners and working towards the ends to the specified torque. The remainder of the installation follows the reverse order of removal.

Before beginning this procedure, allow the engine to cool completely and apply penetrating oil to the manifold and converter fasteners. On 2.7L engines, the exhaust manifold is integrated into the cylinder head, and the turbochargers bolt directly to the cylinder heads. For 2011 through 2014 3.5L and 3.7L models, the front exhaust manifold and the catalytic converter are integrated into one piece, while in 2015 and later 3.5L models, both exhaust manifolds are integrated with the catalytic converters. To remove the front exhaust manifold, disconnect the cable from the negative battery terminal, disconnect the electrical connector for the oxygen sensor and the catalytic converter monitor, and on 2015 and later models, remove the cooling fan shroud assembly. Raise the front of the vehicle and support it securely on jackstands, then disconnect the exhaust Y-pipe from below. Remove the heat shield over the front exhaust manifold, discard the six nuts securing the exhaust manifold, and remove the manifold and converter. Extract the exhaust manifold studs using a stud holding tool or a pair of nuts tightened together over a stud, and discard them. Use a scraper to remove all old gasket material and carbon deposits from the manifold and cylinder head mating surfaces, being cautious not to gouge the aluminum engine parts. Install new exhaust manifold studs with light oil on the threads, place a new manifold gasket over the studs, and install the manifold with new self-locking nuts. Tighten the nuts, starting with the center fasteners and working towards the ends, to the specified torque, and complete the installation in reverse order. For the rear exhaust manifold, disconnect the cable from the negative battery terminal and the connector to the rear bank oxygen sensor, then raise the vehicle and support it securely on jackstands. Remove the Y-pipe-to-catalytic converter flange nuts and disconnect the Y-pipe, and for 2014 and earlier models, remove the rear-bank catalytic converter. Discard the six exhaust manifold mounting nuts and remove the manifold from the engine, along with the manifold gasket. Extract the exhaust manifold studs and discard them, then scrape off all gasket material and carbon deposits from the mating surfaces, taking care with aluminum parts. Install new exhaust manifold studs with light oil on the threads, place a new manifold gasket over the studs, and install the manifold with new self-locking nuts. Tighten the nuts, starting with the center fasteners and working towards the ends, to the specified torque, and complete the installation in reverse order.

Before beginning this procedure, allow the engine to cool completely and apply penetrating oil to the manifold and converter fasteners. On 2.7L engines, the exhaust manifold is integrated into the cylinder head, and the turbochargers bolt directly to the cylinder heads. For 2011 through 2014 3.5L and 3.7L models, the front exhaust manifold and the catalytic converter are integrated into one piece, while in 2015 and later 3.5L models, both exhaust manifolds are integrated with the catalytic converters. To remove the front exhaust manifold, disconnect the cable from the negative battery terminal, disconnect the electrical connector for the oxygen sensor and the catalytic converter monitor, and on 2015 and later models, remove the cooling fan shroud assembly. Raise the front of the vehicle and support it securely on jackstands, then disconnect the exhaust Y-pipe from below. Remove the heat shield over the front exhaust manifold, discard the six nuts securing the exhaust manifold, and remove the manifold and converter. Extract the exhaust manifold studs using a stud holding tool or a pair of nuts tightened together over a stud, and discard them. Use a scraper to remove all old gasket material and carbon deposits from the manifold and cylinder head mating surfaces, being cautious not to gouge the aluminum engine parts. Install new exhaust manifold studs with light oil on the threads, place a new manifold gasket over the studs, and install the manifold with new self-locking nuts. Tighten the nuts, starting with the center fasteners and working towards the ends, to the specified torque, and complete the installation in reverse order. For the rear exhaust manifold, disconnect the cable from the negative battery terminal and the connector to the rear bank oxygen sensor, then raise the vehicle and support it securely on jackstands. Remove the Y-pipe-to-catalytic converter flange nuts and disconnect the Y-pipe, and for 2014 and earlier models, remove the rear-bank catalytic converter. Discard the six exhaust manifold mounting nuts and remove the manifold from the engine, along with the manifold gasket. Extract the exhaust manifold studs and discard them, then scrape off all gasket material and carbon deposits from the mating surfaces, taking care with aluminum parts. Install new exhaust manifold studs with light oil on the threads, place a new manifold gasket over the studs, and install the manifold with new self-locking nuts. Tighten the nuts, starting with the center fasteners and working towards the ends, to the specified torque, and complete the installation in reverse order.

On some models, the catalytic converter is integral with the exhaust manifold, requiring replacement as a unit. The 1.5L and 2.0L models do not utilize a separate exhaust manifold, as it is partially cast into the cylinder head, with the turbocharger mounting directly to it. To begin removal, raise the vehicle and secure it on jackstands. After the engine has cooled, soak the manifold heat-shield retaining nuts with penetrating oil to loosen any rust, then remove the heat shield and apply penetrating oil to the exhaust manifold mounting bolts. For 1.6L engines, remove the turbocharger, while for 2.3L and 2.5L engines, disconnect the exhaust pipe from the exhaust manifold and discard the old flange gasket. Unplug the electrical connector for the oxygen sensor and remove it from the exhaust manifold. Next, remove the exhaust manifold mounting nuts, then take off the exhaust manifold along with the old manifold gasket. Use a stud removal tool or two nuts tightened against each other to extract the old studs from the cylinder head. Inspect the exhaust manifold for cracks or damage, replacing it if necessary. Remove all traces of gasket material from the mating surfaces with care to avoid scratching, and inspect for wear and cracks. Check the exhaust manifold mating surface for warpage using a straightedge and feeler gauge, and determine if replacement or resurfacing is needed. For installation, place new exhaust studs in the cylinder head, install the manifold with a new gasket and self-locking nuts, coating the threads of the exhaust manifold studs with anti-seize compound. Tighten the nuts in several stages, working from the center out, and complete the installation in reverse order of removal. Finally, run the engine and check for exhaust leaks.

Remove the rear-bank catalytic converter.