3. Remove the parts in the order indicated in the Exhaust System following illustration and table. To remove individual parts, only carry out the Material listed steps: Item Specification Part Steps High Temperature Nickel ESE-M12A4-A Extension pipe and 1-3 Anti-Seize Lubricant resonator assembly F6AZ-9L494-AA (in Canada CXG-2-B) Muffler 4-7 Converter assembly 4, 5, 8-14 1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer toSection 100-00.
2. If removing the converter assembly, remove the
transmission crossmember. For additional information, refer to Section 502-00.
Copyright 2002, Ford Motor Company
Last updated: 06/18/2002 2003 Explorer/Mountaineer, 9/2002 309-00-2 Exhaust System 309-00-2
REMOVAL AND INSTALLATION (Continued)
4. To install, reverse the removal procedure.
Item Part Number Description Item Part Number Description
1 — Clamp nut (part of 5202) 6 5A262 Exhaust hanger isolators 2 5A262 Extension pipe isolator Removal Note Removal Note 7 5230 Muffler 3 5202 Extension pipe Installation Note Installation Note 8 — Electrical connectors (part of 4 — Bolts, springs and flag nuts 9F472) (part of 5F264) 9 W708138-S Converter support 5 5E241 Gasket isolator-to-transmission mount bolt (Continued) (Continued)
2003 Explorer/Mountaineer, 9/2002
309-00-3 Exhaust System 309-00-3
REMOVAL AND INSTALLATION (Continued)
Item Part Number Description Item 14: Heated Oxygen Sensor Removal Note 10 5E269 Converter support isolator 1. If installing a new converter, remove the heated 11 Converter-to-manifold nuts oxygen sensors. 12 5F250 Catalytic converter assembly Removal Note Item 15: Catalytic Converter Heat Shield Installation Note Removal Note 13 9F472 Catalyst monitor sensor 1. Inspect the exhaust system for loose or missing Removal Note heat shields or foreign material trapped between Installation Note the heat shields and the exhaust system 14 9F472 Heated oxygen sensor components. Removal Note Installation Note 2. If any heat shields are loose, install worm gear 15 — Catalytic converter heat shield clamps. Removal Note • Use one of the following clamps: 5. Check and, if necessary, align the exhaust FOTZ-5A231-A or W705949-S300. system. For additional information, refer • Trim off the excess ear of the worm clamp. toExhaust System Alignment in this section.
Items 2 and 6: Exhaust Hanger Isolators
Removal Note
CAUTION: Do not use oil- or grease-based
lubricants on the isolators. They may cause deterioration of the rubber.
CAUTION: Oil- or grease-based lubricants
on the isolators may cause the exhaust hanger insulator to separate from the exhaust hanger bracket during vehicle operation. 1. To ease removal and installation of the exhaust components, lubricate the insulators with water. 3. If the heat shields are missing, install new heat shields or exhaust system components as Item 12: Catalytic Converter Assembly Removal necessary. Note Item 14: Heated Oxygen Sensor Installation Note 1. If removing the converter assembly, the transmission crossmember must be removed. 1. Make sure to apply anti-seize to the threads of For additional information, refer to Section the sensors before installation. 502-00. Item 13: Catalyst Monitor Sensor Installation 2. Use a suitable jackstand to support the catalytic Note converter near the rear outlet. Use caution 1. Make sure to apply anti-seize to the threads of removing the catalytic converter. Make sure not the sensors before installation. to damage the manifold outlet flare, the converter inlet flare or the studs.
Item 13: Catalyst Monitor Sensor Removal Note
1. If installing a new converter, remove the catalyst monitor sensors.
2003 Explorer/Mountaineer, 9/2002
309-00-4 Exhaust System 309-00-4
REMOVAL AND INSTALLATION (Continued)
Item 12: Catalytic Converter Assembly Item 7: Muffler Installation Note Installation Note 1. Make sure that the tab on the muffler outlet 1. Clean the mating surfaces of the manifold outlet pipe is seated inside the notch on the extension flare and the catalytic converter inlet flare. Also pipe before tightening the exhaust clamp. clean the mating surfaces of the inlet pipe and the catalytic converter. Support the catalytic Item 3: Extension Pipe Installation Note converter near the rear outlet. Make sure not to 1. Make sure that the tab on the muffler outlet damage the manifold outlet flare, the converter pipe is seated inside the notch on the extension inlet flare or the studs. To correctly seat the pipe before tightening the exhaust clamp. converter, alternately tighten the exhaust manifold-to-catalytic converter nuts to specification.