Ford 9L8Z-5E212-D
Catalytic Converter, Rear

Service and repair of the catalytic converter should begin by securely hoisting the vehicle into NEUTRAL position. Detach the electrical connector of the Catalyst Monitor Sensor (CMS) only on 2.5L vehicles. One must use hand tools to detach the spring nuts which bind the catalytic converter to the exhaust intermediate pipe/exhaust Y-pipe and the resonator to the muffler using a side-to-side alternation while loosening both 10-mm and 8-mm nuts. The exhaust hangers should be carefully removed and you should discard both gaskets while taking out the catalytic converter and muffler assembly together. Cut the exhaust system for 2.5L as well as 3.0L and 2.5L Hybrid vehicles. Install the exhaust hanger insulators by using the correct specifications and check for any signs of damage before making replacements. Thoroughly clean every surface that will be sealed by the flanges. The service clamp should be fitted onto the catalytic converter section before secure attachment between the converter and muffler sections. Inspect all parts of the exhaust intermediate pipe and exhaust Y-pipe and resonator flange studs for damage then replace stained components. The C-Frame with Screw Installer/Remover should be used to remove damaged 10-mm or 8-mm studs which need replacing while maintaining correct alignment with the knurl grooves. Install the exhaust pipe together with the catalytic converter and the muffler assembly onto its three hangers. The installer should install a new resonator-to-muffler gasket without rotating it while tightening two new 8-mm resonator-to-muffler spring nuts in three stages from 5 Nm (44 lb-in) to 10 Nm (89 lb-in), and finally to 17 Nm (150 lb-in) through alternating tightening. The converter-to-exhaust intermediate/exhaust Y-pipe gasket requires two new 10-mm spring nuts which should be tightened in three specific stages until they reach 5 Nm (44 lb-in), 15 Nm (133 lb-in), and finally 25 Nm (18 lb-ft). The four service clamp nuts should be tightened to reach 47 Nm torque (35 lb-ft torque).