Ford 4L3Z-5230-B
Muffler W/Tpipe, Front

Becoming ready for repairing the muffler and tailpipe requires first positioning the vehicle in NEUTRAL in a hoist. Oily substances must never be applied to isolators due to their harmful effect on rubber materials. Always follow the procedure for extension pipe-to-muffler assembly coupling loosening because a new extension pipe and coupling assembly needs replacement. First loosen each coupling of the exhaust intermediate pipe with the muffler and tailpipe, then remove the bolt and the front muffler exhaust bracket and isolator from the frame followed by disconnecting the rear muffler exhaust bracket and isolator before removing the tailpipe exhaust bracket and isolator. Start the muffler and tailpipe assembly removal process by taking out the corresponding components. Start installation from the front of the vehicle and wait to tighten fasteners until you finish component assembly and alignment. Scrape away all rust that appears on the exhaust clamp surface through use of an abrasive pad. After putting the muffler and tailpipe assembly in position begin installing the front muffler exhaust hanger bracket and its isolator to the frame until it reaches 20 Nm (15 ft. lbs.). Second in the sequence comes the installation of the rear muffler exhaust hanger bracket and isolator on the frame tight to 20 Nm (15 ft. lbs.) Next comes the tailpipe exhaust hanger bracket and isolator which also requires tight to 20 Nm (15 ft. lbs.). The exhaust system requires final alignment before tightening all exhaust system clamps.

Safety allows the dual converter Y-pipe service and repair on the LH side through hoisting the vehicle in NEUTRAL mode first. Service operations on the LH heated oxygen sensor and catalyst monitor sensor requires disconnecting their electrical connectors. The service technician should first remove and then discard the converter-to-manifold nuts on the LH side. 4x4 vehicles with transmission type 411100 require removal of two bolts holding the heat shield to its transmission support crossmember. The transmission needs support by contact points on its oil pan rails although high-lift jacks serve as suitable support methods to prevent internal harm. Begin by removing the transmission mount nuts and proceed with taking off the LH and RH bolts and nuts while extracting the transmission support crossmember. Begin by removing the bolt. After which you must perform converter removal on all vehicles by loosening the torque clamp nut. It is essential to delay all fastener tightening until every component is fully assembled while you should initially start tightening fasteners from the vehicle front end. Perform a cleaning operation on the mating surfaces while paying attention to avoid damage to the studs or nozzle and flares of both the manifold and catalytic converter. It is essential to use fresh gaskets together with exhaust fasteners. The installation process ends with following the steps for removing the converter.

Start the muffler and tailpipe repairs only after securing the vehicle into NEUTRAL position on a hoist. Application of oil or grease based lubricants on the isolators should be avoided because they cause the rubber to deteriorate thus separating the exhaust hanger bracket from its position during operation. When a new exhaust intermediate pipe requires installation with a Torca(R) clamp assembly then both components must be added. To remove the muffler and tailpipe assembly start by loosening the exhaust intermediate pipe-to-muffler and tailpipe assembly clamp followed by securing front, rear, and tailpipe exhaust hanger bracket bolts from the frame. The first step for installation requires the use of an abrasive pad to clean surface rust from the exhaust Torca(R) clamp area before positioning the muffler and tailpipe assembly. Place the front and rear and tailpipe exhaust hanger brackets and isolators onto the frame before tightening them using 30 Nm torque (22 lb-ft). Push the tailpipe assembly forward for the collar on the hanger bracket to meet the isolator while the insertion button of the extension pipe inlet passes fully into the L-notch of the tailpipe assembly. You should install the new exhaust intermediate pipe-to-muffler assembly Torca(R) clamp during the installation of a new exhaust intermediate pipe and apply torque of 47 Nm (35 lb-ft) to the exhaust intermediate pipe-to-muffler and tailpipe assembly exhaust clamp. Conduct the exhaust system alignment procedure before moving on because the exhaust system isolators remain at non-zero loads.

Remove the two bolts securing the heat shield to the transmission support crossmember.

Loosely slide the exhaust Y-pipe-dual catalytic converter-to-exhaust intermediate pipe coupling into place, then align the exhaust system and tighten all exhaust system clamps.

Clean the exhaust coupling surface area of any surface rust.

Align the exhaust system and tighten all clamps securely.

A new exhaust intermediate pipe and clamp assembly must be installed.