Ford Mustang (1999-2004) Service Manual: Exhaust System (Description and Operation)
WARNING: The normal operating temperature of the exhaust system is very high. Never attempt to repair any part of the system until it has cooled. Be especially careful when working around the three way catalytic converter. The temperature of the three way catalytic converter rises to a high level after only a few minutes of engine operation.
CAUTION: When repairing exhaust system or removing exhaust components, disconnect all heated oxygen sensors (HO2S) at the wiring connectors to prevent damage to the heated oxygen sensors and wiring harness. For additional information, refer to Section for location of the heated oxygen sensors.
The exhaust system:
- contains dual three-way catalytic converters.
- has a crossover pipe downstream of the three way catalytic converters (4.6L).
- has two upstream heated oxygen sensors mounted before the three-way catalytic converters.
- the production muffler and tailpipe assembly is a one-piece design exhaust system.
Exhaust System - 3.8L
Exhaust System - 4.6L (2V)
Exhaust System - 4.6L (4V)
Exhaust System
Torque Specifications
...
Exhaust System (Diagnosis and Testing)
Symptom Chart
Condition
Possible Sources
Action
Noisy or
leaking
exhaust
Broken or loose
clamps, hangers or
isolators.
Punctures in the muffler
( ...
Other materials:
Disassembly
1. Remove the driveshaft (4602). For additional information, refer to
Driveshaft in this section.
2. CAUTION: Under no circumstances is the driveshaft assembly to be
clamped in the
jaws of a vise or similar holding fixture. Denting or localizing fracture ca ...
Material
Item
Specification
Threadlock and
Sealer
E0AZ-19554-AA
WSK-M2G351-A5 (type
II)
Shoulder Bolt Kit
F5ZZ-76539A04-A
-
NOTE: Before starting the adjustment process, inspect the top for damage,
make sure that the door
window glass ...
Pinpoint Tests
NOTE: Reinstall or install new evaporative emission hose clamps
removed or damaged during testing
procedures.
PINPOINT TEST A: DTC P0442 SMALL LEAK IN EVAP SYSTEM
Test Step
Result / Action to Take
NOTE: Condition P0442 DTC set: less than 0.62 ...