Ford Mustang (1999-2004) Service Manual: Dual Converter Y-Pipe - 3.8L
Removal
NOTE: The RH and LH catalytic converters are serviceable separately.
1. Raise and support the vehicle. For additional information, refer to Section.
2. CAUTION: When repairing the exhaust system or removing exhaust components, disconnect all heated oxygen sensors (HO2S) (9F472) and catalyst monitor sensors at the wiring connectors to prevent damage to the sensors and wiring harnesses.
Disconnect the RH and LH HO2S connectors.
3. Disconnect the RH and LH catalyst monitor sensor connectors.
4. Remove the dual converter assembly nuts.
5. Remove the RH exhaust manifold flange nuts.
6. Remove the LH exhaust manifold flange nuts.
7. Remove the dual converter (5F250) assembly.
8. If necessary, use the two spot welds as a baseline, measure 226.8 mm (9.07 in) and cut the pipe.
9. Remove 13 mm (0.52 in) from the LH dual converter.
Installation
1. Position the LH dual converter.
- Snug the LH converter-to-manifold nuts.
2. Position the RH dual converter pipe.
- Snug the RH converter-to-manifold nuts.
3. If necessary, position the LH and RH dual converter pipes into the sleeve and install the clamps.
Tighten the clamps to 55 Nm (41 lb-ft).
4. Install the dual converter assembly nuts.
5. Tighten the LH converter-to-manifold nuts.
6. Tighten the RH converter-to-manifold nuts.
7. Connect the RH and LH HO2S connectors.
8. Connect the RH and LH catalyst monitor sensor connectors.
9. Lower the vehicle.
Muffler - 4.6L (4V)
Removal and Installation
1. Raise and support the vehicle. For additional information, refer to
Section.
2. NOTE: RH side shown, LH side similar.
Remove the dual converter assembly nuts.
3. Remove ...
Dual Converter H-Pipe - 4.6L (2V and 4V)
Removal
NOTE: The RH and LH catalytic converters are serviced separately.
1. Raise and support the vehicle. For additional information, refer to
Section.
2. CAUTION: When repairing exhaust system or ...
Other materials:
Gear (Removal and Installation)
Special Tool(s)
Teflon Seal Replacer Set
211-D027 (D90P-3517-A) or
Equivalent
Tie Rod End Remover
211-001 (TOOL-3290-D)
Removal
1. Turn the steering wheel as necessary to position the wheels in the
straight-ahead position. Do
not loc ...
Crash sensors and airbag indicator
WARNING: Modifying or adding equipment to the front end of
your vehicle (including frame, bumper, front end body structure
and tow hooks) may affect the performance of the airbag system,
increasing the risk of injury. Do not modify the front end of your
vehicl ...
Refrigerant System Tests
Special Tool(s)
R-134a Manifold Gauge Set
176-R032A or equivalent
1. Connect the R-134a Manifold Gauge Set. For additional information, refer
to Manifold Gauge
Set Connection in this section.
2. Adjust the climate controls for maximum cooling ...