Exhaust fasteners are of a torque prevailing design, and only new fasteners with the same part number as the original should be used, with specified torque values during reassembly to ensure correct retention of exhaust components. For four-cylinder engines, raise the vehicle securely on jackstands, remove the downstream oxygen sensor/catalyst sensor from the catalyst, loosen the clamp fasteners securing the front end of the catalyst to the turbocharger, and if threads are damaged or rusted, apply penetrant before loosening. Remove the nuts and bolts securing the flange at the rear end of the catalyst to the exhaust pipe, then remove the catalytic converter, taking care not to scratch or gouge the flanges. Discard the old gasket between the exhaust down pipe and the catalyst mounting flange, and installation is the reverse of removal using a new gasket and fasteners tightened to the specified torque. For V6 engines, remove and discard the two upper catalytic converter-to-exhaust manifold bolts and gasket from the front or rear catalytic converter, raise the front of the vehicle securely on jackstands, and remove the engine under-cover. If removing the front catalytic converter, remove the bracket bolt, then discard the two lower catalytic converter nuts and remove the front or rear catalytic converter, inspecting the bracket clamp and installing a new clamp if necessary. Installation is the reverse of removal using a new flange gasket. For the 3.5L engine, raise the front of the vehicle securely on jackstands, remove the engine under-cover, locate and disconnect the upstream and downstream oxygen sensors, and remove both sensors. If equipped with a heat shield, remove the heat shield bolts and the shield from the exhaust manifold, and if necessary, remove another heat shield protecting the steering gear assembly. Remove the heat shield mounting bracket fasteners, and on the left side converter, remove the bolts and position aside the Electronic Power Assist Steering shield. For AWD models, remove the transaxle support insulator and anti-roll cover. Remove the catalyst upper mounting flange-to-exhaust manifold fasteners, applying penetrant if threads are damaged or rusted, and if equipped, remove the skid plate retainers and the skid plate. Remove the lower mounting flange-to-exhaust pipe fasteners, pull the exhaust pipe down to clear the lower end of the catalyst, and then remove the catalyst from the exhaust manifold. Discard the old gaskets between the exhaust manifold flange and the upper catalyst flange and, if equipped, between the lower catalyst flange and the exhaust pipe flange, with installation being the reverse of removal using new flange gaskets.
Posted by FordPartsGiant Specialist 
