TORQUE SPECIFICATIONS
| Description | Nm |
|---|---|
| Exhaust Y-pipe - dual catalytic converter heat shield clamp screws | 7 |
| Exhaust Y-pipe - dual catalytic converter-to-exhaust manifold nuts a | |
| Muffler-to-catalytic converter bolts | 40 |
| Service exhaust coupler | 47 |
| Torca® clamp | 48 |
TORQUE SPECIFICATIONS
a Refer to procedure in this article.
The exhaust system consists of the following
- Exhaust Y-pipe dual catalytic converter
- Muffler
- Tailpipe
The exhaust system provides an exit for exhaust gases and reduces engine noise by passing exhaust gases through the catalytic converter 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 exhaust Y-pipe dual catalytic converter, muffler and tailpipe are installed separately.
Precautions
| CAUTION | 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. |
| CAUTION | 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. |
| CAUTION | 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. |
| CAUTION | 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.
Note. Always install new gasket and nuts whenever an exhaust joint containing these is loosened.
Make sure to follow these precautions when carrying out the procedures in this article.
Special Tools Illustration Tool Name Tool Number Electronic Vibration Analyzer 100-F027 (014-00344) or equivalent
Scheme 1
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
- Verify the concern by running the engine (with the vehicle on the ground) or road testing the vehicle to duplicate the condition.
- Visually inspect the components of the exhaust system and related controls that may affect exhaust gas quality or loss of power.
- Visually inspect for obvious signs of mechanical damage. Refer to the following chart. VISUAL INSPECTION CHART Mechanical Exhaust pipe pinched or crushed Damaged muffler Broken or damaged exhaust hanger brackets Damaged catalytic converter Cracked exhaust manifold Dirty engine air cleaner Loose or damaged heat shields (4.6L only)
- Verify that the exhaust system is installed correctly, with clamps correctly located and tightened to specification.
- If the fault is not visually evident, determine the symptom. Go to «Symptom Chart - Exhaust System»(/ford/explorer-sport-trac/ii-2006-2010/remont/exhaust/#exhaust-system) or Go to «Symptom Chart - Noise, Vibration and Harshness (NVH)»(/ford/explorer-sport-trac/ii-2006-2010/remont/exhaust/#exhaust-system) .
| Condition | Possible Sources | Action |
|---|---|---|
| Vehicle has low or no power - vehicle performance complaint | Exhaust pipe pinched or crushed Damaged catalytic converter Loose obstruction in exhaust | INSPECT the exhaust components for damage. REPAIR or INSTALL new components as necessary. TEST the system for normal operation. If the concern is still present, REFER to the Introduction - Gasoline Engines article for restricted exhaust. |
| Restricted exhaust (possible frozen condensate in muffler) | CHECK drain holes for foreign material. PARK the vehicle inside to thaw. TEST vehicle for normal operation. If concern is still present, REFER to the Introduction - Gasoline Engines article. | |
| Burning smell - usually occurs at idle with possible traces of smoke | Foreign material caught in exhaust system Missing heat shields (4.6L only) Fluid leak on exhaust | INSPECT the exhaust system for foreign material or missing heat shields. REPAIR or INSTALL new components as necessary. TEST the system for normal operation after the repair. |
| Odor - described as a sulfur or rotten egg smell | Catalytic converter | At times, a slight sulfur smell is normal for catalytic converters. The cause is the sulfur content in the gasoline being used. ADVISE customer, no repair required. |
| Rich fuel conditions Misfire conditions Excessive sulfur content in fuel | REFER to the Introduction - Gasoline Engines article. | |
| Visible rust on surface of exhaust pipes | Catalytic converter/exhaust system | Surface rust is a characteristic of materials used on exhaust systems. Exposure to heat or road salt may result in surface rust. INSPECT for perforations. If there are no perforations, condition is normal. |
Symptom Chart - Exhaust System
Symptom Chart - Noise, Vibration and Harshness (NVH)
Note. Noise, vibration and harshness (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 AND HARSHNESS article. 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 AND HARSHNESS article for the next likely system and continue diagnosis.
| Condition | Possible Sources | Action |
|---|---|---|
| Rattle, squeaks or buzz type noise - from the bottom of vehicle | Loose or damaged heat shield (4.6L only) | INSPECT the exhaust system for loose or missing heat shields or foreign material trapped between the heat shields and the exhaust system components. If any heat shields are loose, INSTALL either worm gear clamp FOTZ-5A231-A or W705949-S300 and tighten to 7 Nm (62 lb-in). If the heat shields are missing, INSTALL new heat shields or exhaust system components as necessary. If a rattle, noise or buzz condition persists, INSTALL a new heat shield or component as necessary. TEST the system for normal operation after the repair. |
| Loose or damaged exhaust isolators | CHECK that the exhaust isolators are correctly installed. INSPECT the exhaust isolators for wear or damage. INSTALL new isolators as necessary. TEST the system for normal operation after the repair. | |
| Damaged exhaust isolator hanger bracket | INSPECT the exhaust system components for damage or broken hangers. INSTALL new components as necessary. CHECK for loose or damaged exhaust hanger brackets or fasteners. TIGHTEN bolts to specification or INSTALL new components as necessary. TEST the system for normal operation after the repair. | |
| Catalytic converter Muffler | MOVE the exhaust system to simulate the bouncing action of the vehicle, checking for exhaust-to-body contact while moving the exhaust system. Using a rubber mallet, lightly TAP on the exhaust components one at a time to duplicate the noise concern. DETERMINE if there are any loose or broken baffles or element. REPAIR or INSTALL new components as necessary. TEST the system for normal operation after the repair. | |
| Exhaust grounded to chassis | INSPECT for signs of exhaust components-to-body contact. If necessary, CARRY OUT the Exhaust System Alignment . | |
| Drone or clunk type noise - from bottom of vehicle | Loose or damaged exhaust isolators | INSPECT exhaust isolators for wear or damage. INSTALL new isolators as necessary. TEST the system for normal operation after the repair. |
| Exhaust grounded to chassis | INSPECT for signs of exhaust components-to-body contact. If necessary, CARRY OUT the Exhaust System Alignment . | |
| Whistles, boom, hum or ticking type noise - noise tends to change as engine warms. Noises are often accompanied by exhaust fumes | Exhaust system leak | INSPECT the entire exhaust system for leaks. CHECK for punctures, loose or damaged clamps/fasteners, gaskets, sensors or broken welds. EXAMINE the chassis for grayish-white or black exhaust soot, which would indicate exhaust leakage at that point. To magnify a small leak, have an assistant hold a shop towel over the tailpipe outlet, while listening for a leak. REPAIR or INSTALL new components as necessary. TEST the system for normal operation after the repair. |
| Catalytic converter Muffler | MOVE the exhaust system to simulate the bouncing action of the vehicle, checking for exhaust-to-body contact while moving the exhaust system. Using a rubber mallet, lightly TAP on the exhaust components one at a time to duplicate the noise concern. DETERMINE if there are any loose or broken baffles or element. REPAIR or INSTALL new components as necessary. TEST the system for normal operation after the repair. | |
| Exhaust muffler/resonator drain hole enlarged due to corrosion | NOTE: Check with vehicle on the ground, not on a hoist. CONFIRM drain holes are noise source. INSTALL new components as necessary. TEST the system for normal operation after the repair. | |
| Thermal expansion of exhaust versus heat shields (4.6L only) | This is a normal condition. | |
| Hissing or rushing noise - high frequency sound. Vehicle performance is unaffected | Exhaust system. Exhaust flow through pipes | MOVE the exhaust system to simulate the bouncing action of the vehicle, checking for exhaust-to-body contact while moving the exhaust system. Using a rubber mallet, lightly TAP on the exhaust components one at a time to duplicate the noise concern. DETERMINE if there are any loose or broken baffles or element. CHECK for missing or leaking Torca® clamps. REPAIR or INSTALL new components as necessary. TEST the system for normal operation after the repair. |
| Pinging noise - occurs when exhaust system is hot, engine turned off | Catalytic converter/exhaust system Thermal expansion of exhaust system | Cool down pinging is the exhaust system expanding and contracting during heating and cooling. This is a normal condition. |
| Vibration - occurs at idle and at low speeds. Also accompanied by clunk or buzz type noise | Loose or damaged exhaust isolators | INSPECT the exhaust isolators for wear or damage. INSTALL new isolators as necessary. TEST the system for normal operation after the repair. |
| Loose or damaged exhaust isolator hanger brackets | INSPECT the exhaust isolator hanger brackets for wear or damage. INSTALL or REPAIR as necessary. TEST the system for normal operation after the repair. | |
| Exhaust system grounded to chassis | CARRY OUT the Exhaust System Alignment . | |
| Engine drumming noise - normally accompanied by vibration | Damaged or misaligned exhaust system | INSPECT the exhaust system for loose or damaged fasteners, Torca® clamps or isolators. CARRY OUT the Exhaust System Alignment . TEST the system for normal operation after the repair. |
| Sputter type noise - noise worse when cold, lessens or disappears when the vehicle is at operating temperature | Damaged or worn exhaust system | INSPECT the exhaust system for leaks or damage. REPAIR as necessary. TEST the system for normal operation after the repair. |
| Thumping noise - from the bottom of the vehicle, worse at acceleration | Misaglined exhaust system | CHECK the exhaust system-to-chassis clearance. CHECK the exhaust system isolators for damage. REPAIR as necessary. TEST the system for normal operation after the repair. |
| Engine vibration - is felt with increases and decreases in engine RPM | Strain on exhaust system isolators | CARRY OUT the Exhaust System Alignment . REPAIR as necessary. TEST the system for normal operation after the repair. |
| Drumming noise - occurs inside the vehicle during idle or high idle, hot or cold. Very low-frequency drumming is very RPM dependent | Exhaust system vibration excites the body resonances inducing interior noise. | Go to Pinpoint Test A . |
| NOTE |
|---|
| Check with vehicle on the ground, not on a hoist. |
Symptom Chart - Noise, Vibration and Harshness (NVH)
Pinpoint Test A: Drumming Noise
This pinpoint test is intended to diagnose the following
- Exhaust system
- A1 CHECK THE EXHAUST SYSTEM Key in START position. Increase the engine RPM until the noise is the loudest. Note the engine RPM. Key in OFF position. 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. Key in START position. Increase the engine RPM and listen for the drumming noise. Note the engine RPM if the noise occurs. Key in OFF position. Using a vibration analyzer (VA), 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/explorer-sport-trac/ii-2006-2010/remont/exhaust/#exhaust-system) . TEST the system for normal operation. NO : CONDUCT a diagnosis on other suspect systems. REFER to «NOISE, VIBRATION AND HARSHNESS»(/ford/explorer-sport-trac/ii-2006-2010/remont/oem-general-information/#noise-vibration-and-harshness) article.
All vehicles
| CAUTION | 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. Use only water-based lubricants on the isolators. |
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.
Note. Always install new gasket and nuts whenever an exhaust joint is loosened.
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
- Loosen all fasteners joining the exhaust system components.
- Position the exhaust Y-pipe dual catalytic converter to the exhaust manifold and loosely tighten all nuts to stiffen the joint enough to maintain position. Tighten to 8 Nm (71 lb-in) and then add additional torque if needed to stiffen the joint.
- Tighten the muffler assembly-to-tailpipe Torca® clamp. Tighten to 48 Nm (35 lb-ft).
- Confirm that the exhaust isolators are at zero load.
- If equipped, and not welded to the muffler inlet pipe, make sure that the service exhaust coupler is against the alignment nub and is positioned approximately at the 2 o'clock position facing the muffler. If the muffler inlet pipe does not have an alignment nub, center the exhaust coupler over the muffler inlet pipe joint and position it at approximately the 2 o'clock position facing the muffler. Tighten to 47 Nm (35 lb-ft).
- If equipped, and not welded to the muffler inlet pipe, make sure that the service exhaust coupler is against the alignment nub and is positioned approximately at the 2 o'clock position facing the muffler. If the muffler inlet pipe does not have an alignment nub, center the exhaust coupler over the muffler inlet pipe joint and position it at approximately the 2 o'clock position facing the muffler. Tighten to 47 Nm (35 lb-ft).
- Confirm that the exhaust isolators are at zero load.
- Tighten the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts. Tighten to 40 Nm (30 lb-ft).
- Confirm that the exhaust isolators are at zero load.
- Tighten the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. Tighten to 40 Nm (30 lb-ft).
- Confirm that the exhaust isolators are at zero load.
- Start the engine and check the exhaust system for leaks.
Torca® Clamp
- Remove the nut from the Torca® clamp.
- Grind the spot weld from the Torca® clamp and remove the clamp.
- Clean the uneven surface area and, using an abrasive pad, clean the Torca® clamp surface area of any rust on the pipe.
- Position a new Torca® clamp 3-4 mm (0.12-0.16 in) from the button slot.
- Rotate the Torca® clamp until it is 83 to 93 degrees from slot in the side of pipe.
Note. Vehicle body removed for clarity.
Scheme 2
| Item | Part Number | Description |
|---|---|---|
| 1 | 5212 | Tailpipe |
| 2 | 5221 | Tailpipe-to-muffler assembly Torca® clamp |
| 3 | 5K214 | Muffler assembly |
| 4 | 5G215 | Muffler-to-catalytic converter bolt (2 required) |
| 5 | 5E241 | Gasket |
| 6 | N807634 | Muffler-to-catalytic converter nut (2 required) |
| 7 | 5F250 | Exhaust Y-pipe dual catalytic converter |
| 8 | W701706 | Exhaust Y-pipe dual catalytic converter-to-exhaust manifold nut (4 required) |
| 9 | Heated oxygen sensors (HO2S) electrical connectors (part of 12B637) | |
| 10 | Catalyst monitor sensor electrical connectors (part of 12B637) | |
| 11 | Muffler inlet pipe (part of 5K244) | |
| 12 | 5A281 | Exhaust coupler (service part) |
| 13 | Muffler (part of 5K244) | |
| 14 | Muffler inlet pipe with welded on exhaust coupler (service part) (part of 5D256) | |
| 15 | Muffler (service part) (part of 5D256) |
Note. Vehicle body removed for clarity.
Scheme 3
| Item | Part Number | Description |
|---|---|---|
| 1 | 5202 | Tailpipe |
| 2 | 5221 | Tailpipe-to-muffler assembly Torca® clamp |
| 3 | 5K214 | Muffler assembly |
| 4 | 5G215 | Muffler-to-catalytic converter bolt (2 required) |
| 5 | 5E241 | Gasket |
| 6 | N807634 | Muffler-to-catalytic converter nut (2 required) |
| 7 | 5F250 | Exhaust Y-pipe dual catalytic converter |
| 8 | W705443 | Exhaust Y-pipe dual catalytic converter-to-exhaust manifold nut (4 required) |
| 9 | Heated oxygen sensors (HO2S) electrical connectors (part of 12B637) | |
| 10 | Catalyst monitor sensor electrical connectors (part of 12B637) | |
| 11 | Muffler inlet pipe (part of 5K244) | |
| 12 | 5A281 | Exhaust coupler (service part) |
| 13 | Muffler (part of 5K244) | |
| 14 | Muffler inlet pipe with welded on exhaust coupler (service part) (part of 5D256) | |
| 15 | Muffler (service part) (part of 5D256) |
Note. Vehicle body removed for clarity.
Note. Premier exhaust shown, standard exhaust similar.
Scheme 4
| Item | Part Number | Description |
|---|---|---|
| 1 | 5212 | Tailpipe |
| 2 | 5221 | Tailpipe-to-muffler assembly Torca® clamp |
| 3 | 5K214 | Muffler assembly |
| 4 | 5G215 | Muffler-to-catalytic converter bolt (2 required) |
| 5 | 5E241 | Gasket |
| 6 | N807634 | Muffler-to-catalytic converter nut (2 required) |
| 7 | 5F250 | Exhaust Y-pipe dual catalytic converter |
| 8 | W701706 | Exhaust Y-pipe dual catalytic converter-to-exhaust manifold nut (4 required) |
| 9 | Heated oxygen sensors (HO2S) electrical connectors (part of 12B637) | |
| 10 | Catalyst monitor sensor electrical connectors (part of 12B637) |
Note. Vehicle body removed for clarity.
Note. Premier exhaust shown, standard exhaust similar.
Scheme 5
| Item | Part Number | Description |
|---|---|---|
| 1 | 5202 | Tailpipe |
| 2 | 5221 | Tailpipe-to-muffler assembly Torca® clamp |
| 3 | 5K214 | Muffler assembly |
| 4 | 5G215 | Muffler-to-catalytic converter bolt (2 required) |
| 5 | 5E241 | Gasket |
| 6 | N807634 | Muffler-to-catalytic converter nut (2 required) |
| 7 | 5F250 | Exhaust Y-pipe dual catalytic converter |
| 8 | W705443 | Exhaust Y-pipe dual catalytic converter-to-exhaust manifold nut (4 required) |
| 9 | Heated oxygen sensors (HO2S) electrical connectors (part of 12B637) | |
| 10 | Catalyst monitor sensor electrical connectors (part of 12B637) |
- For additional information, refer to the procedures in this article.
REMOVAL
| CAUTION | 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. Use only water-based lubricants on the isolators. |
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.
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
- Using a suitable jack, support the exhaust system.
- Disconnect the heated oxygen sensor (HO2S) and the catalyst monitor sensors electrical connectors.
- Remove the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts, nuts and gasket. Discard the exhaust Y-pipe dual catalytic converter-to-muffler assembly nuts and gasket.
- Remove the transmission support crossmember. For additional information, refer to «FULL FRAME AND BODY MOUNTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/frames-subframes-crossmembers/#full-frame-and-body-mounting) article.
- Remove the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. Discard the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts.
- Remove the exhaust Y-pipe dual catalytic converter.
INSTALLATION
- Position the exhaust Y-pipe dual catalytic converter to the exhaust manifold and loosely tighten all nuts to stiffen the joint enough to maintain position. Tighten to 8 Nm (71 lb-in) and then add additional torque if needed to stiffen the joint.
- Install the exhaust Y-pipe-dual catalytic converter-to-muffler assembly new gasket, bolts and new nuts. Tighten to 40 Nm (30 lb-ft).
- Tighten the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. Tighten to 40 Nm (30 lb-ft).
- Install the transmission support crossmember. For additional information, refer to «FULL FRAME AND BODY MOUNTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/frames-subframes-crossmembers/#full-frame-and-body-mounting) article.
- Connect the HO2S and catalyst monitor sensors electrical connectors.
- 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 the «Exhaust System Alignment»(/ford/explorer-sport-trac/ii-2006-2010/remont/exhaust/#exhaust-system) .
All vehicles
| CAUTION | 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. Use only water-based lubricants on the isolators. |
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.
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
- Using a suitable jack, support the exhaust system.
- Using a suitable exhaust cutter, cut the muffler inlet pipe between the first bend coming out of the muffler and the next bend in line. If a service exhaust coupler is present at this point, loosen the service exhaust coupler nuts and separate the muffler inlet pipe.
- Using a suitable exhaust cutter, cut the muffler inlet pipe between the first bend coming out of the muffler and the next bend in line. If a service exhaust coupler is present at this point, loosen the service exhaust coupler nuts and separate the muffler inlet pipe.
- Loosen the muffler assembly-to-tailpipe Torca® clamp.
- Remove the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts, nuts and gasket. Discard the exhaust Y-pipe dual catalytic converter-to-muffler assembly nuts and gasket.
- Disconnect the rubber isolators and remove the muffler assembly.
All vehicles
- Position the muffler assembly and connect the rubber isolators.
- Position the muffler assembly-to-tailpipe and make sure the tab on the muffler assembly is seated inside the notch on the tailpipe and then tighten the Torca® clamp. Tighten to 48 Nm (35 lb-ft).
- If reusing the factory muffler assembly, position the 2 halves of the muffler inlet pipe into the service exhaust coupler and center the service exhaust coupler onto the cut joint on the muffler inlet pipe. If installing a new service muffler kit, install the muffler inlet pipe coming out of the muffler into the service exhaust coupler.
- If not welded to the muffler inlet pipe, make sure that the service exhaust coupler is against the alignment nub and is positioned approximately at the 2 o'clock position facing the muffler. If the muffler inlet pipe does not have an alignment nub, center the exhaust coupler over the muffler inlet pipe joint and position it at approximately the 2 o'clock position facing the muffler. Tighten to 47 Nm (35 lb-ft).
- If reusing the factory muffler assembly, position the 2 halves of the muffler inlet pipe into the service exhaust coupler and center the service exhaust coupler onto the cut joint on the muffler inlet pipe. If installing a new service muffler kit, install the muffler inlet pipe coming out of the muffler into the service exhaust coupler.
- If not welded to the muffler inlet pipe, make sure that the service exhaust coupler is against the alignment nub and is positioned approximately at the 2 o'clock position facing the muffler. If the muffler inlet pipe does not have an alignment nub, center the exhaust coupler over the muffler inlet pipe joint and position it at approximately the 2 o'clock position facing the muffler. Tighten to 47 Nm (35 lb-ft).
- Install the exhaust Y-pipe-dual catalytic converter-to-muffler assembly new gasket, bolts and new nuts. Tighten to 40 Nm (30 lb-ft).
- 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 the «Exhaust System Alignment»(/ford/explorer-sport-trac/ii-2006-2010/remont/exhaust/#exhaust-system) .
| CAUTION | 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. Use only water-based lubricants on the isolators. |
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.
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
- Loosen the muffler assembly-to-tailpipe Torca® clamp.
- Disconnect the rubber isolator and remove the tailpipe.
- Position the tailpipe and connect the rubber isolator.
- Position the muffler assembly-to-tailpipe and make sure the tab on the muffler assembly is seated inside the notch on the tailpipe and then tighten the Torca® clamp. Tighten to 48 Nm (35 lb-ft).
- 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 the «Exhaust System Alignment»(/ford/explorer-sport-trac/ii-2006-2010/remont/exhaust/#exhaust-system) .