Ford XL3Z-9430-GA Exhaust Manifold Assembly

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To remove the exhaust manifold, first disconnect the negative battery cable and securely raise the vehicle on jackstands, ensuring to turn off the air suspension switch if applicable. Disconnect the oxygen sensor electrical connector and apply penetrating oil to the exhaust Y-pipe-to-manifold studs and nuts, which may be rusty. Remove the nuts securing the exhaust Y-pipe to the exhaust manifolds, using heat if necessary to loosen them. For the right manifold, disconnect the EGR tube, and for the left manifold, remove the nut holding the oil dipstick tube support and pull the dipstick tube out. Next, remove the mounting bolts to separate the exhaust manifold(s) from the cylinder head, noting the locations of the bolts and studs while removing old gaskets. Before installation, check the exhaust manifold for cracks and ensure the bolt threads are clean and undamaged, cleaning the mating surfaces thoroughly. If replacing the manifold, remove the oxygen sensor, clean its threads, and apply high-temperature anti-seize compound before transferring it to the new manifold. Position the new manifold and gasket on the cylinder head, installing the mounting bolts and studs, and if warpage is present, install pilot bolts first and elongate holes if necessary. When tightening the bolts, start with the center pair, followed by the front and rear pairs, using a torque wrench to ensure proper tightness in three equal steps. Finally, the remaining steps follow the reverse order of removal, and after installation, start the engine to check for exhaust leaks.

To remove the exhaust manifold, first disconnect the cable from the negative battery terminal and, for 4WD models, remove the front driveshaft. Next, remove the nut and move the power brake booster vacuum hose support bracket. Raise the vehicle and support it securely on jackstands. Apply penetrating oil to the exhaust pipe-to-manifold studs and nuts, as they are often corroded or rusty, and also to the EGR pipe fitting on the left exhaust manifold. Remove the nuts retaining the exhaust pipes to the manifolds, and on the left side, remove the nut and bracket securing the oil dipstick tube. For 2005 and later Expedition/Navigator models, lock the steering column in the straight-ahead position and disconnect the lower steering shaft bolt to allow moving the shaft aside for the left exhaust manifold removal. Remove the EGR pipe fitting from the left exhaust manifold and the eight mounting nuts from each manifold, noting that these nuts are difficult to access, requiring a flex-socket and various-length extensions. Before installation, check the exhaust manifolds for cracks and ensure the bolt threads are clean and undamaged, with clean mating surfaces for the exhaust manifold and cylinder head. Position a new gasket and slip the exhaust manifold over the studs, then install the mounting nuts. Tighten the nuts from the rear to the front, alternating between top and bottom rows, in three equal steps to the specified torque. The remaining installation steps follow the reverse order of removal, and when reconnecting the EGR tube to the left manifold, apply a slight amount of anti-seize compound on the threads. Finally, start the engine and check for exhaust leaks.

Start the engine and check for exhaust leaks. If working on a 5.0L model, have the air conditioning system recharged by the shop that discharged it.

Disconnect the cable from the negative battery terminal. On 4WD models, remove the front driveshaft.

Remove the eight exhaust manifold bolts.

Clean them up with a thread chaser or replace them. To replace damaged exhaust manifold studs, "double-nut" them.

Disconnect the oxygen sensor electrical connector.

Disconnect the oxygen sensor electrical connectors.

Disconnect the oxygen sensor electrical connector(s).