Exhaust System Alignment

All vehicles

NOTE: Exhaust fasteners are of a torque prevailing design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .

2. Loosen the muffler assembly-to-intermediate pipe ball clamps.

3. Loosen the Torca® coupler nuts.
   • Do not tighten the coupler at this time.

5.0L only

4. Loosen the catalytic converter-to-exhaust H-pipe ball clamps.

All vehicles

5. Loosen the catalytic converter-to-manifold nuts.
   • Do not tighten the coupler at this time.

6. Position an adjustable jackstand under the catalytic converter Y-pipe/H-pipe.

7. Make sure the 3 muffler assembly hooks are correctly inserted into all of the muffler exhaust isolators.

8. Beginning at the front of the vehicle, align the exhaust system in the following sequence.
   1. Evenly tighten all 4 of the catalytic converter-to-exhaust manifold nuts (starting with the right lower, then the left lower, then the right upper, then the left upper) in 10 Nm (89 lb-in) increments until reaching the final torque of 40 Nm (30 lb-ft).
   2. (5.0L only) Tighten the catalytic converter-to-exhaust H-pipe ball clamp nuts to 30 Nm (22 lb-ft).

   3. NOTE: Make sure that the intermediate pipe and converter Y-pipe/H-pipe is inserted into the Torca® coupler correctly.

      NOTE: While tightening the Torca® couplers and the muffler assembly-to-intermediate pipe ball clamp nuts, make sure the intermediate pipe to fuel tank and the intermediate pipe to fuel tank straps have a minimum clearance of 25 mm (0.984 in). The intermediate pipe to fuel vapor line minimum clearance should also be no less than 15 mm (0.59 in). On the 5.8L, make sure the intermediate pipe-to-axle coolant lines has a minimum clearance of 10 mm (0.393 in).

      Slide Torca® coupler over the converter Y-pipe/H-pipe and engage the coupler clip completely over the converter button.
   4. Tighten the Torca® couplers to 48 Nm (35 lb-ft).
   5. Verify the intermediate pipe is fully seated in the muffler inlet pipe.
      • Tighten the muffler assembly-to-intermediate pipe ball clamp nuts to 30 Nm (22 lb-ft).

9. Start the engine and check the exhaust system for leaks.