Ford 3F2Z-5G203-CA
Front Pipe

You should service the exhaust system after the vehicle enters NEUTRAL position and gets hoisted while the system has properly cooled down because exhaust temperatures reach their peak near the 3-way catalytic converter. Lubricate exhaust isolators hangers only with rubber-safe products to prevent rubber degradation and avoid separation of exhaust isolator hangers from hanger brackets. The repair process requires new fasteners with identical part numbers to the originals and torque values according to specifications for ensuring exhaust components stay in place. Remove and discard the two converter-to-flex pipe bolts and place new gaskets and bolts before fastening them up to 40 Nm (30 ft. lbs.). The flex pipe-to-catalytic converter bolts which cannot be detached should either be cut or ground at their bolt heads followed by flex pipe assembly removal before grinding the remaining bolt section at the flange surface. The process requires setting a center punch on the remaining bolt then drilling it out with a 10.5-mm (0.41 inch) (13/32-inch) drill bit followed by surface cleaning of the mating sections before installing the service bolts, service flag nuts and new gasket. First replace the exhaust flexible pipe-to-muffler clamp and the tailpipe clamp with a new clamp after tightening it to 47 Nm torque. Heating the exhaust flexible pipe-to-muffler and tailpipe joint will help with their removal. It is important to wait until all components are correctly positioned before starting any fastener tightening task which needs to begin at the front end of the vehicle.

Determine the service position for exhaust work by using NEUTRAL mode with a vehicle positioned on a hoist. Initial steps require removal of the catalytic converter-to-flex pipe bolts before installation of new gaskets and bolts which should be tightened to 40 Nm (30 ft. lbs). The flex pipe-to-catalytic converter bolt removal requires drill and grinding of the bolt when it does not come off. Remove the flex pipe assembly and complete drilling the remained part in the flange surface after removal. The remaining bolt requires center punching before drilling it out with a 10.5-mm (0.41 inch) (13/32-inch) drill bit. The installation requires service bolt N806408-S60, service flag nut W705839-S441 as well as a new gasket for mating clean surfaces between flex pipe and catalytic converter prior to assembly. Follow the steps of removing and discarding the exhaust flexible pipe-to-muffler and tailpipe clamp before installing a new clamp while setting the torque to 47 Nm (35ft.lbs). For successful removal of the exhaust flexible pipe-to-muffler and tailpipe joint it sometimes requires heat application. Reinstallation requires delay of all fastener tightening operations until complete component assembly then progressive tightening started from the vehicle's front end.