Ford 6F2Z-5230-AB
Muffler & Pipe, Rear

Always service the muffler and tailpipe when the exhaust system temperature has reduced because the 3-way catalytic converter area becomes particularly hot. Using oil or grease-based lubricants on the isolators will cause rubber deterioration that might result in the exhaust isolator hanger separating from the exhaust hanger bracket when in operation. When fastening new exhaust components use parts that match the original numbers and follow torque specifications to maintain proper retention. Start the process with a neutral gear vehicle on a hoist system where a suitable jack supports the exhaust system. The technician should detach the ground strap from the exhaust hanger before protecting the flex pipe with a splint and tie straps to avoid overbending it. Use new exhaust flexible pipe-to-muffler and tailpipe clamps while tightening them to 47 Nm (35 ft. lbs). Start by removing the track bar through the disconnection of the track bar bolt combined with body detachment followed by reinstallation of the bolt at 90 Nm (66 ft. lbs). The technician might need to apply heat to the exhaust flexible pipe-to-muffler and tailpipe joint region to simplify removal. Disconnect the exhaust isolator hangers at three points then take out the muffler combined with the tailpipe. Reassembly must start with the front of the vehicle and all components need to be in place before any fasteners are tightened while inspecting exhaust system alignment.

Service the muffler and tailpipe only when the exhaust system achieves safe room temperature because the 3-way catalytic converter operates at extremely high temperatures. Do not use oil or grease-based lubricants on isolators because they will cause rubber deterioration which could result in exhaust isolator hanger-separation from exhaust hanger bracket during operational use. New fasteners with the identical original part number are required because exhaust fasteners use torque prevailing technology so strictly follow torque specifications for correct exhaust component retention. Start the repair procedure with the vehicle in NEUTRAL gear and on a hoisting station. A suitable jack should be used to secure the exhaust system before disconnecting the ground strap from the exhaust hanger. Excessive bending or twisting of the flex pipe should be avoided so support it with a flex pipe-length splint secured by tie straps. Use a new clamp to fasten the exhaust flexible pipe-to-muffler and tailpipe while torquing it to 47 Nm (35 ft. lbs.). The track bar must be removed by uninstalling its bolt and detaching it from the body frame before you tighten it to 90 Nm (66 ft. lbs.) during reinstallation. A heat source may help loosen the joint between the exhaust flexible pipe and the muffler to simplify its removal process. The technician must detach all three exhaust isolator hangers after which he can remove the assembly that includes the muffler and tailpipe. Establish the starting point for fastener tightening at the front region of the vehicle and then proceed in backward order. Exhaust system alignment must also be checked before completion.