Exhaust System -- E-Series Ford Cutaway E350 Super Duty

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

The 6.0L diesel exhaust system consists of the following

1. Turbocharger inlet Y-pipe
2. Catalytic converter
3. Exhaust downpipe
4. Extension pipe (if equipped)
5. Muffler and tail pipe assembly

The gasoline exhaust system consists of the following

1. Exhaust Y-pipe with catalytic converter (van/wagon)
2. Exhaust Y-pipe without catalytic converter (stripped chassis)
3. Catalytic converter (stripped chassis)
4. Extension pipe (if equipped)
5. Muffler and tail pipe assembly

The exhaust system provides an exit for exhaust gases and reduces engine noise by passing exhaust gases through the catalytic converters and a muffler assembly. Rubber exhaust hanger isolators attach the exhaust system to the mounting hooks.

Catalytic Converter

The catalytic converter plays a major role in the emission control system. The catalytic converter operates as a gas reactor. Its catalytic function is to speed the heat-producing chemical reaction of components in the exhaust gases in order to reduce air pollutants. The catalyst material inside the catalytic converter consists of a ceramic substrate.

The catalytic converter is designed to provide a long life. No maintenance is necessary for the catalytic converter.

Sound Insulators and Shields

Sound insulators and shields attached to the underbody protect the vehicle from exhaust system heat and should be inspected at regular intervals to make sure they are not dented or out of position. If a sound insulator and shield is damaged or shows evidence of deterioration, a new sound insulator and shield should be installed. The sound insulators and shields for the turbocharger inlet Y-pipe, exhaust Y-pipe, exhaust downpipe, catalytic converter, extension pipe and muffler and tail pipe assembly are installed separately.

Precautions

Note. Do not use leaded fuel in a vehicle equipped with a catalytic converter. In a vehicle that is continually misfueled, the lead in the fuel will be deposited in the catalytic converter and completely blanket the catalyst. Lead reacts with platinum to "poison" the catalyst. Continuous use of leaded fuel can destroy the catalyst and render the catalytic converter useless.

Note. The addition of lead to the catalytic converter can also solidify the catalyst, causing excessive back pressure in the exhaust system and possibly causing engine damage.

Note. Extremely high temperatures (1,100°C [2,012°F] or above) due to misfiring or over-rich fuel/air mixture will cause the ceramic substrate to sinter or burn, destroying the catalytic converter. Do not continue to operate the vehicle if the engine is misfiring, there is a power loss or other unusual operating conditions, such as engine overheating and backfiring.

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

Note. Exhaust fasteners are of a prevailing torque 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.

Make sure to follow these precautions when carrying out the appropriate procedures.

Principles of Operation

The exhaust system provides an exit for exhaust gases and reduces engine noise by passing exhaust gases through the catalytic converters and a muffler assembly. The catalytic converters also play a major role in reducing air pollutants.

Inspection and Verification

1. Verify the concern by running the engine (with the vehicle on the ground) or road testing the vehicle to duplicate the condition.
2. Visually inspect the components of the exhaust system and related controls that may affect exhaust gas quality or loss of power.
3. Visually inspect for obvious signs of mechanical damage. Refer to the following chart. VISUAL INSPECTION CHART Mechanical Exhaust pipe pinched or crushed Cracked exhaust manifold Damaged turbocharger inlet Y-pipe (6.0L diesel) Damaged exhaust Y-pipe (gasoline engines) Damaged downpipe (6.0L diesel) Damaged catalytic converter Damaged extension pipe (if equipped) Damaged muffler and tail pipe assembly Loose or damaged sensors or sensor mountings Broken or damaged exhaust hanger brackets Dirty engine air cleaner Loose or damaged heat shields
4. Verify that the exhaust system is installed correctly, with clamps correctly located and tightened to specification.
5. If the fault is not visually evident, determine the symptom. GO to «SYMPTOM CHART - EXHAUST SYSTEM»(/ford/cutaway-e350-super-duty/2008-2012/remont/exhaust/#exhaust-system-e-series__symptom-chart-exhaust-system) or GO to «SYMPTOM CHART - NVH»(/ford/cutaway-e350-super-duty/2008-2012/remont/exhaust/#exhaust-system-e-series__symptom-chart-nvh) .

Symptom Chart - Exhaust System

SYMPTOM CHART - EXHAUST SYSTEM

Symptom Chart - NVH

Note. NVH symptoms should be identified using the diagnostic tools that are available. For a list of these tools, an explanation of their uses and a glossary of common terms, refer to NOISE, VIBRATION & HARSHNESS . Since it is possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a process of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system for the symptom, refer back to NOISE, VIBRATION & HARSHNESS for the next likely system and continue diagnosis.

SYMPTOM CHART - NVH

Normal Operation

The diesel exhaust system provides an exit for exhaust gases and reduces engine noise by passing exhaust gases through the catalytic converters and a muffler assembly.

Note. The vehicle can have a lack/loss of power, odor, a noise or a "no start" concern. These concerns may be related to the exhaust system. Carry out the following test, if no trouble codes were stored. This test is for diagnosing the source for these conditions.

This pinpoint test is intended to diagnose the following

1. Restricted or damaged pipes
2. Muffler
3. Catalytic converter

PINPOINT TEST A: LOSS OF POWER

1. A1 EXHAUST SYSTEM INSPECTION Inspect the exhaust system for damage or deterioration. Look for cracks, punctures, leaks, loose connections, dents or unusual bending. Is the exhaust system OK? Yes: GO to A2 . No: REPAIR or INSTALL new any damaged or deteriorated exhaust components. TEST the system for normal operation.
2. A2 EXHAUST SYSTEM FROZEN Inspect the exhaust system for frozen condensation. Park the vehicle inside to thaw. Is the restriction gone? Yes: Exhaust system is OK. No: GO to A3 .
3. A3 BACK PRESSURE TEST Position the vehicle on a hoist. Refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) . Remove the muffler and tail pipe assembly. Refer to «MUFFLER AND TAILPIPE»(/ford/cutaway-e350-super-duty/2008-2012/remont/exhaust/#exhaust-system-e-series) or «MUFFLER AND TAILPIPE - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/exhaust/#exhaust-system-e-series) . Start the engine and gradually increase the engine speed to 2,000 rpm with the transmission in NEUTRAL. Is the restriction gone? Yes: INSTALL a new muffler and tail pipe assembly. No: GO to A4 .
4. A4 BACK PRESSURE TEST Remove the catalytic converter assembly. Refer to «CATALYTIC CONVERTER - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/exhaust/#exhaust-system-e-series) . Start the engine and gradually increase the engine speed to 2,000 rpm with the transmission in NEUTRAL. Is the restriction gone? Yes: INSTALL a new catalytic converter assembly. No: No indications of a restriction have been detected. CONDUCT a diagnosis on other suspect systems. CLEAR the DTCs.

Pinpoint Test B: Drumming Noise

This pinpoint test is intended to diagnose the following

1. Exhaust system

1. B1 CHECK THE EXHAUST SYSTEM Start the engine. Increase the engine rpm until the noise is the loudest. Note the engine rpm. Ignition OFF. Add approximately 9 kg (20 lb) of weight to the exhaust system. First place the weight at the tail pipe and test, then at the front pipe. Start the engine. Increase the engine rpm and listen for the drumming noise. Note the engine rpm if the noise occurs. Ignition OFF. Determine the amount of vibration that occurs with the drumming noise. Is the noise/vibration reduced or eliminated, or does the noise/vibration occur at a different rpm? Yes: REFER to «EXHAUST SYSTEM ALIGNMENT»(/ford/cutaway-e350-super-duty/2008-2012/remont/exhaust/#exhaust-system-e-series__exhaust-system-alignment) . TEST the system for normal operation. No: CONDUCT a diagnosis on other suspect systems. REFER to «NOISE, VIBRATION & HARSHNESS»(/ford/cutaway-e350-super-duty/2008-2012/remont/oem-general-information/#noise-vibration-harshness) .

Exhaust System Alignment

All vehicles

Exhaust System Alignment - 6.0L Diesel

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Loosen all fasteners joining the exhaust system components.
3. Beginning at the rear of the vehicle, the exhaust system should be aligned to establish the maximum clearance to its surrounding components. Make sure all fit pipes are pushed all the way into the preceding pipe and the pipe notches are fully seated and correctly lined up with the tabs.
4. Tighten the muffler and tail pipe assembly-to-catalytic converter (or if equipped extension pipe) Torca® clamp. Tighten to 55 Nm (41 lb-ft).
5. If equipped, tighten the extension pipe-to-catalytic converter Torca® clamp. Tighten to 55 Nm (41 lb-ft).
6. Tighten the exhaust downpipe-to-turbocharger clamp. Tighten to 9 Nm (80 lb-in).
7. Tighten the exhaust downpipe-to-catalytic converter nuts. Tighten to 40 Nm (30 lb-ft).
8. Start the engine and check the exhaust system for leaks.

Scheme 1

Scheme 2

1. Remove the nut from the Torca® clamp.
2. Grind the spot weld from the Torca® clamp and remove the clamp.
3. Clean the uneven surface area and, using an abrasive pad, clean the Torca® clamp surface area of any rust on the pipe.
4. Position a new Torca® clamp 0-3 mm (0-0.12 in) from the button slot.
5. Rotate the Torca® clamp until it is 83 to 93 degrees from the slot in the side of the pipe.

Exhaust System, Van/Wagon

Note. Vehicle body removed from art for clarity.

Scheme 3

PARTS DESCRIPTION CHART

Exhaust System, Stripped Chassis (5-Speed Transmission)

Note. 5.4L shown in illustration, 6.8L similar.

Vehicle body removed from art for clarity.

Scheme 4

PARTS DESCRIPTION CHART

Exhaust System, 6.0L Diesel Engine

Note. Vehicle body removed from art for clarity.

Scheme 5

PARTS DESCRIPTION CHART

1. For additional information, refer to the appropriate procedure(s).

Removal and Installation

Note. Exhaust fasteners are of a prevailing torque 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.

Scheme 6

Scheme 7

Scheme 8

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .
3. Disconnect the Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS) electrical connectors.
4. Support the muffler and tail pipe assembly with a safety stand.
5. Release the front muffler and tail pipe assembly from the hanger isolator.
6. Loosen the muffler and tail pipe assembly-to-exhaust Y-pipe Torca® clamp. To install, tighten to 55 Nm (41 lb-ft).
7. Remove the muffler and tail pipe assembly from the exhaust Y-pipe.
8. Remove the 2 LH and 1 RH heat shield-to-crossmember bolts. To install, tighten to 10 Nm (89 lb-in).
9. Remove the 2 crossmember-to-rear transmission mount nuts. To install, tighten to 95 Nm (70 lb-ft).
10. Support the rear of the transmission with a safety stand.
11. Remove the 2 RH and 2 LH transmission crossmember-to-frame nuts and 4 bolts and remove the transmission crossmember. To install, tighten to 81 Nm (60 lb-ft).
12. Remove the 4 exhaust Y-pipe-to-exhaust manifold nuts and discard. Remove the exhaust Y-pipe from the vehicle. To install, tighten the 2 new upper exhaust Y-pipe-to-exhaust manifold nuts to 40 Nm (30 lb-ft) then tighten the 2 new lower exhaust Y-pipe-to-exhaust manifold nuts to 40 Nm (30 lb-ft).
13. To install, reverse the removal procedure. If a new Torca® clamp needs to be installed, refer to «TORCA® CLAMP»(/ford/cutaway-e350-super-duty/2008-2012/remont/exhaust/#exhaust-system-e-series) .

Note. Exhaust fasteners are of a prevailing torque 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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Support the muffler and tail pipe assembly and catalytic converter with a safety stand.
3. Release the front muffler and tail pipe assembly and (if equipped, the extension pipe) isolators.
4. Remove the 3 exhaust Y-pipe-to-catalytic converter nuts and discard. Remove the exhaust Y-pipe-to-catalytic converter support bracket. To install, tighten the new nuts to 40 Nm (30 lb-ft).
5. Position the catalytic converter and muffler and tail pipe assembly rearward from the exhaust Y-pipe and discard the gasket.
6. Disconnect the Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS) electrical connectors.
7. Remove the 2 LH and 1 RH heat shield-to-crossmember bolts. To install, tighten to 10 Nm (89 lb-in).
8. Remove the 2 crossmember-to-rear transmission mount nuts. To install, tighten to 95 Nm (70 lb-ft).
9. Support the rear of the transmission with a safety stand.
10. Remove the 2 RH and 2 LH transmission crossmember-to-frame nuts and 4 bolts and remove the transmission crossmember. To install, tighten to 81 Nm (60 lb-ft).
11. Remove the 4 exhaust Y-pipe-to-exhaust manifold nuts and discard. Remove the exhaust Y-pipe. To install, tighten the new upper exhaust Y-pipe-to-exhaust manifold nuts to 40 Nm (30 lb-ft) then tighten the new lower exhaust Y-pipe-to-exhaust manifold nuts to 40 Nm (30 lb-ft).
12. To install, reverse the removal procedure.

Note. Exhaust fasteners are of a prevailing torque 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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Support the muffler and tail pipe assembly with a safety stand.
3. Release the front muffler and tail pipe assembly and, if equipped, the extension pipe hanger isolators.
4. Loosen the muffler and tail pipe assembly or, if equipped, the extension pipe-to-catalytic converter Torca® clamp. To install, tighten to 55 Nm (41 lb-ft).
5. Remove the muffler and tail pipe and, if equipped, the extension pipe from the catalytic converter.
6. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.
7. Remove the 3 exhaust Y-pipe-to-catalytic converter nuts and discard. Remove the exhaust Y-pipe-to-catalytic converter support bracket. To install, tighten the new nuts to 40 Nm (30 lb-ft).
8. Remove the catalytic converter from the exhaust Y-pipe and discard the gasket.
9. To install, reverse the removal procedure. If a new Torca® clamp needs to be installed, refer to «TORCA® CLAMP»(/ford/cutaway-e350-super-duty/2008-2012/remont/exhaust/#exhaust-system-e-series) .

All vehicles

Note. Exhaust fasteners are of a prevailing torque 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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .
3. Remove the turbocharger-to-exhaust downpipe clamp. To install, tighten to 9 Nm (80 lb-in).
4. Remove the 2 exhaust downpipe-to-catalytic converter nuts and discard. Remove the exhaust downpipe from the vehicle. To install, tighten the new nuts to 40 Nm (30 lb-ft).
5. To install, reverse the removal procedure.

Note. Exhaust fasteners are of a prevailing torque 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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Support the muffler and tail pipe assembly with a safety stand.
3. Release the front muffler and tail pipe assembly and, if equipped, the extension pipe hanger insulator(s).
4. Loosen the muffler and tail pipe assembly or, if equipped, the extension pipe-to-catalytic converter Torca® clamp. To install, tighten to 55 Nm (41 lb-ft).
5. Remove the muffler and tail pipe assembly and, if equipped, the extension pipe from the catalytic converter.
6. Release the catalytic converter hanger isolator.
7. Remove the 2 exhaust downpipe-to-catalytic converter nuts and discard. To install, tighten the new nuts to 40 Nm (30 lb-ft).
8. Remove the catalytic converter from the exhaust downpipe.
9. To install, reverse the removal procedure. If a new Torca® clamp needs to be installed, refer to «TORCA® CLAMP»(/ford/cutaway-e350-super-duty/2008-2012/remont/exhaust/#exhaust-system-e-series) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Support the muffler and tail pipe assembly with a safety stand.
3. Release all the muffler and tail pipe assembly hanger isolators.
4. Loosen the muffler Torca® clamp. To install, tighten to 55 Nm (41 lb-ft).
5. If equipped with a tail pipe extension, loosen the tail pipe extension Torca® clamp and remove the tail pipe extension from vehicle. To install, tighten to 55 Nm (41 lb-ft).
6. Remove the RH rear upper shock absorber nut. To install, tighten to 40 Nm (30 lb-ft).
7. Remove the RH rear lower shock absorber nut and the shock absorber. To install, tighten to 80 Nm (59 lb-ft).
8. Remove the muffler and tail pipe assembly from the catalytic converter or, if equipped, the extension pipe.
9. Remove the muffler and tail pipe assembly.
10. To install, reverse the removal procedure. If a new Torca® clamp needs to be installed, refer to «TORCA® CLAMP»(/ford/cutaway-e350-super-duty/2008-2012/remont/exhaust/#exhaust-system-e-series) .

Material

MATERIAL SPECIFICATIONS

Scheme 9

PARTS DESCRIPTION CHART

Scheme 10

Scheme 11

Scheme 12

Scheme 13

1. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .
2. Remove the 2 LH turbocharger inlet Y-pipe-to-exhaust manifold bolts and 2 nuts. Discard the nuts.
3. Remove the 2 RH turbocharger inlet Y-pipe-to-exhaust manifold bolts and 2 nuts. Discard the nuts.
4. Remove the turbocharger inlet Y-pipe-to-EGR cooler clamp. Discard the gasket.
5. Remove the turbocharger-to-turbocharger inlet Y-pipe clamp.
6. Carefully remove the turbocharger inlet Y-pipe assembly from the vehicle.

Installation

Note. Only tighten the turbocharger inlet Y-pipe fasteners with hand tools or damage to the turbocharger inlet pipe may occur.

Note. When installing the turbocharger inlet Y-pipe into the vehicle, do not bend or twist the flex bellows or damage to the flex bellows may occur.

Scheme 14

Scheme 15

1. If the turbocharger inlet Y-pipe was separated, install the gasket and loosely install the 2 bolts and 2 new nuts.
2. Position the turbocharger inlet Y-pipe into the vehicle.
3. Position the turbocharger-to-turbocharger inlet Y-pipe clamp.
4. Install the new metal gasket on the EGR cooler and align the turbocharger inlet Y-pipe to the EGR cooler. Position the clamp.
5. Apply anti-seize lubricant to the turbocharger inlet Y-pipe-to-exhaust manifold bolts, then install the 4 bolts and 4 new nuts.
6. Tighten the turbocharger-to-turbocharger inlet Y-pipe clamp. Tighten to 12 Nm (106 lb-in).
7. Tighten the turbocharger inlet Y-pipe-to-EGR cooler clamp. Tighten to 6 Nm (53 lb-in).
8. Make sure the turbocharger inlet Y-pipe is correctly aligned to the exhaust manifolds. Using hand tools, alternately tighten the 4 bolts to draw the turbocharger inlet Y-pipe to the exhaust manifold. There should be an equal gap spacing between the turbocharger inlet Y-pipe and the exhaust manifold flange at the top and bottom bolts.
9. Alternately tighten the 4 turbocharger inlet Y-pipe-to-exhaust manifold bolts. Tighten to 27 Nm (20 lb-ft).
10. If loosened, tighten the 2 turbocharger inlet Y-pipe nuts at the RH to LH joint. Tighten to 27 Nm (20 lb-ft).
11. Check the systems for leaks.
12. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .

See also:
• INTRODUCTION - GASOLINE MODELS
• NOISE, VIBRATION & HARSHNESS
• JACKING & LIFTING
• INTERIOR TRIM AND ORNAMENTATION
• SYMPTOM CHART - EXHAUST SYSTEM
• SYMPTOM CHART - NVH
• PINPOINT TEST A
• EXHAUST SYSTEM ALIGNMENT
• PINPOINT TEST B
• MUFFLER AND TAILPIPE