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.

Dual Converter Y-Pipe - 3.8L

3. Disconnect the RH and LH catalyst monitor sensor connectors.

Dual Converter Y-Pipe - 3.8L

4. Remove the dual converter assembly nuts.

Dual Converter Y-Pipe - 3.8L

5. Remove the RH exhaust manifold flange nuts.

Dual Converter Y-Pipe - 3.8L

6. Remove the LH exhaust manifold flange nuts.

Dual Converter Y-Pipe - 3.8L

7. Remove the dual converter (5F250) assembly.

Dual Converter Y-Pipe - 3.8L

8. If necessary, use the two spot welds as a baseline, measure 226.8 mm (9.07 in) and cut the pipe.

Dual Converter Y-Pipe - 3.8L

9. Remove 13 mm (0.52 in) from the LH dual converter.

Dual Converter Y-Pipe - 3.8L

Installation

1. Position the LH dual converter.

  • Snug the LH converter-to-manifold nuts.

Dual Converter Y-Pipe - 3.8L

2. Position the RH dual converter pipe.

  • Snug the RH converter-to-manifold nuts.

Dual Converter Y-Pipe - 3.8L

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.

Dual Converter Y-Pipe - 3.8L

5. Tighten the LH converter-to-manifold nuts.

Dual Converter Y-Pipe - 3.8L

6. Tighten the RH converter-to-manifold nuts.

Dual Converter Y-Pipe - 3.8L

7. Connect the RH and LH HO2S connectors.

8. Connect the RH and LH catalyst monitor sensor connectors.

9. Lower the vehicle.

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