Ford 5C3Z-5F250-A
Catalytic Converter

The procedure to service and repair a gasoline engine catalytic converter requires first placing the vehicle in NEUTRAL position then hoisting it for work. Crush the skid plate only if present. Dispose of both the 4 Y-pipe exhaust flange nuts in addition to the gasket. The coupling between the catalytic converter and muffler needs to be loosened. AlsoDisconnect the exhaust intermediate pipe from its isolator if it has one and the front muffler isolator if it exists. Remove the catalytic converter while unwiring its rubber isolator. Any installation of a new catalytic converter requires complete removal of catalyst monitor sensors. Apply anti-seize compound on the catalyst monitor sensor threads before installing it and torque it to 46 Nm (34 ft. lbs.). After cleaning the gasket area between the exhaust Y-pipe flange and the catalytic converter flange position the converter then restore the rubber isolator to its original position. Use the front muffler isolator to connect the exhaust intermediate pipe in case the application requirements allow for it. New exhaust Y-pipe flange gaskets should be installed before the new exhaust Y-pipe flange nuts get loosely fitted. The pipe coupling requires cleaning from any rust at its surface area before installing the new coupling at the joint between the catalytic converter and muffler or the joint between the catalytic converter and exhaust intermediate pipe with a 4 mm (0.15 inch) maximum tolerance from the button end. The exhaust system needs alignment before tightening the exhaust Y-pipe flange nuts to 40 Nm (30 ft. lbs.), then move to tighten either the catalytic converter-to-muffler coupling or catalytic converter-to-exhaust intermediate pipe coupling to 55 Nm (41 ft. lbs.). Install the skid plate when it comes with the system.

The first step to servicing and repairing the catalytic converter on gasoline engines requires placing the vehicle into NEUTRAL as well as installing it on a hoist. Drain off the 4 exhaust Y-pipe flange nuts and the gasket before discarding them. The connection needs loosening either between the catalytic converter and muffler or between the converter and the exhaust intermediate pipe. Disconnect the catalytic converter from the rubber isolator before removing it. The installation of a fresh catalytic converter requires elimination of catalyst monitor sensors. The threads of the catalyst monitor sensor require anti-seize before installation with a torque output of 46 Nm (34 ft. lbs.). Position the catalytic converter correctly before reconnecting the rubber isolator while applying a new exhaust Y-pipe flange gasket and installing flange nuts loosely. Clean the exhaust coupling surface area with an abrasive pad and place the coupling joint on the catalytic converter-to-muffler union or catalytic converter-to-exhaust intermediate pipe union ensuring a maximum spacing of 4 mm (0.15 inch). Place an new exhaust Y-pipe flange gasket then mount the exhaust Y-pipe flange nuts without tightening them. Position the new coupling on the catalytic converter-to-muffler joint or, if equipped, the catalytic converter-to-exhaust intermediate pipe joint but keep it at least 4 mm (0.15 inch) behind the button. The exhaust system requires alignment followed by tightening the exhaust Y-pipe flange nuts to 40 Nm (30 ft. lbs.) and catalytic converter-to-muffler coupling (or converter-to-intermediate exhaust pipe coupling) to 55 Nm (41 ft. lbs.).