Ford 4L5Z-5K238-AA
Extension

The procedure for muffler and tailpipe servicing starts with putting the vehicle into NEUTRAL mode on a hoist. To service the 2.3L engine vehicles requires removal of both exhaust downpipe-to-muffler and tailpipe assembly bolts as well as two flagnuts and a gasket which should be discarded. Vehicles with 4.0L engines require removal of two right-hand side exhaust Y-pipe-to-muffler and tailpipe assembly bolts accompanied by two flagnuts and one gasket that should be discarded together with the flagnuts. The procedure continues with disconnection of three rubber isolators which enables the muffler and tailpipe assembly to be removed. Follow the installation procedure by avoiding oil or grease-based lubricants on the isolators because they cause rubber deterioration. All mating areas of the muffler and tailpipe assembly need cleaning before the components can be reinstalled into the vehicle while attaching the three rubber isolators. The installation of new exhaust downpipe-to-muffler and tailpipe assembly gasket must be followed by torquing two exhaust downpipe-to-muffler and tailpipe assembly bolts along with two new flagnuts to 40 Nm (30 lb-ft). Implement new gasket installation for the 4.0L engine on right-hand exhaust Y-pipe-to-muffler and tailpipe assembly before torquing two right-hand side exhaust Y-pipe-to-muffler and tailpipe assembly bolts and two new flagnuts to 40 Nm (30 lb-ft). Check the exhaust system isolators for zero load before executing an exhaust system alignment procedure.

Begin exhaust system servicing and repair process by placing the vehicle in NEUTRAL mode and hoisting it before proceeding. You need to disconnect the heated oxygen sensor (HO2S) and catalyst monitor sensor electrical connectors followed by removing the bolts seasoning the exhaust downpipe to the muffler and tailpipe assembly while the last step is nulled along with the exhaust manifold to exhaust downpipe nuts. After disconnecting the exhaust downpipe from the transmission mount the isolator-to-transmission bolt should come out. The HO2S and catalyst monitor sensor installation requires threads lubrication with anti-seize before securing both sensors by tightening them to 41 Nm (30 ft. lbs). Place the exhaust downpipe correctly in position without scratching the exhaust manifold outlet flare or the exhaust downpipe inlet flare and also the joining surfaces between exhaust downpipe and muffler and tailpipe. The transmission mount should be reinstalled with the isolator-to-transmission bolt secured at 90 Nm (66 ft. lbs). Begin by loosely installing the exhaust manifold-to-exhaust downpipe nuts and the exhaust downpipe-to-muffler and tailpipe assembly nuts before positioning the exhaust system correctly and reattaching the HO2S and catalyst monitor sensor electrical connectors.

Place the 2.3L vehicle for exhaust downpipe servicing by placing it on a hoist in NEUTRAL position. Disconnect the electrical connectors of both Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS). Separate the exhaust downpipe from the muffler and tailpipe assembly through removal of two bolts and two flagnuts with a gasket that must be discarded. The exhaust manifold next to downpipe requires the removal of two retaining nuts before their disposal. You need to uninstall the transmission mount together with the isolator-to-transmission bolt to detach the exhaust downpipe. Installation should be carried out without oil or grease-based lubricants on isolators since rubber deterioration will occur. Clean every contact point on the exhaust downpipe before settings its proper position into the vehicle. Place the transmission mount with an isolator-to-transmission bolt installed and tighten it at 90 Nm (66 lb-ft). Fasten together two new exhaust downpipe-to-exhaust manifold nuts while tightening them to 40 Nm (30 lb-ft). After placing the exhaust downpipe-to-muffler and tailpipe assembly gasket follow the installation of two exhaust downpipe-to-muffler and tailpipe assembly bolts with two new flagnuts and tighten to 40 Nm (30 lb-ft). The final step requires reconnecting HO2S and CMS electrical connectors after which technicians should validate the exhaust system isolators maintain zero load position; additional exhaust system alignment must occur if zero load is not achieved.

Remove the bolts, flagnuts, and gasket, discarding the flagnuts and gasket.