Ford 7S4Z-5G203-C
Exhaust Pipe

The repair and servicing of exhaust flexible pipes must begin with the vehicle positioned on a hoist facing NEUTRAL. Too much bending or twisting of the exhaust flexible pipe creates the risk of damage happening. The pipe needs either a support wrap or appropriate splint to maintain its position. Start by eliminating the two exhaust flexible pipe nuts from the muffler assembly connection while using new studs which need proper torque of 47 Nm (35 ft. lbs.). Proceed by removing two nuts holding the exhaust flexible pipe in place at the converter then extract the pipe while retailing new studs (47 Nm - 35 ft. lbs. torque). During installation continue by following the removal steps while including new gaskets and fresh nuts in the process.

The production muffler and tailpipe assembly is built into one piece but the service version contains three pieces for Partial Zero Emissions Vehicles (PZEV) and two pieces for non-PZEV. The installation of service sections requires the production exhaust system to be cut at an accurate position before moving forward. Position the vehicle at NEUTRAL mode on a hoist. A support wrap or splint must be added around the exhaust flexible pipe to stop bending or twisting that would harm the pipe. The PZEV removal procedure includes taking out the two exhaust flexible pipe nuts which must be discarded alongside the gasket. The removal process for non-PZEV requires separating the two muffler tailpipe connector nuts while removing both nuts along with the gasket. The muffler-tailpipe assembly must be separated from both front exhaust hanger isolators before cutting the exhaust system according to specifications. Remove the front muffler section by disconnecting the two exhaust hanger isolators followed by the rear muffler section. Install the exhaust hanger isolators with attention to their correct specification to prevent damage to the components. Inspection for wear and fatigue should occur and damaged parts require immediate replacement. Start with the installation of a non-tightened front muffler service section using a service clamp. The next step involves placing the rear muffler service section followed by hanger isolator attachment on the rear exhaust. The front section of the muffler requires a service clamp that connects to the rear section before installation of four exhaust hanger isolators on the front assembly. The service clamps should be tightened to reach 47 Nm (35 lb-ft) torque. The installation of non-PZEV requires a new gasket between the catalytic converter and muffler and tailpipe assembly with two new nuts tightened up to 47 Nm (35 lb-ft). To install the exhaust flexible pipe on PZEV vehicles users must use new gasket installation between the muffler and tailpipe assembly while tightening two new nuts to 47 Nm (35lb-ft). Terminate support to the exhaust flexible pipe while making sure the conduit remains straight and not twisted since both issues may harm the system.

Remove and discard the two nuts and take out the exhaust flexible pipe, also discarding the gasket.

47 Nm (35 lb-ft).

Excessively bending or twisting the exhaust flexible pipe, as this may cause damage.