309-00-1 Exhaust System 309-00-1

REMOVAL AND INSTALLATION

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
REMOVAL AND INSTALLATION (Continued)
Item 12: Catalytic Converter Assembly
Installation Note
1. Clean the mating surfaces of the manifold outlet
flare and the catalytic converter inlet flare. Also
clean the mating surfaces of the inlet pipe and
the catalytic converter. Support the catalytic
converter near the rear outlet. Make sure not to
damage the manifold outlet flare, the converter
inlet flare or the studs. To correctly seat the
converter, alternately tighten the exhaust
manifold-to-catalytic converter nuts to
specification.
309-00-4
Item 7: Muffler Installation Note
1. Make sure that the tab on the muffler outlet
pipe is seated inside the notch on the extension
pipe before tightening the exhaust clamp.
Item 3: Extension Pipe Installation Note
1. Make sure that the tab on the muffler outlet
pipe is seated inside the notch on the extension
pipe before tightening the exhaust clamp.
2003 Explorer/Mountaineer, 9/2002