Ford Mustang (1999-2004) Service Manual: Exhaust System (Diagnosis and Testing)

Ford Mustang (1999-2004) Service Manual / Exhaust System / 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 (5230).
  • Broken, loose or missing exhaust manifold fasteners or gaskets.
  • Loose heated oxygen or catalyst monitor sensor.
  • REPAIR as necessary.
  • Exhaust system misalignment.

 

  • Broken or loose catalyst internal components.
  • REPAIR as necessary.

 

 

 

 

 

 

  • ALIGN exhaust system.

 

  • LOOSEN all fasteners joining the exhaust system and SHAKE the system to isolate the concern. REPAIR as necessary
  • Loss of power
  • Kinked or damaged exhaust pipe.
  • Clogged three-way catalytic converter (5F250).
  • Foreign object in the exhaust system.
  • REPAIR as necessary.
    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 ...

    Muffler - 3.8L
    Removal and Installation 1. Raise and support the vehicle. For additional information, refer to Section. 2. Support the rear axle with a suitable jack. 3. Remove the upper arm-to-differential bolt. ...

    Other materials:

    Disc and Pressure Plate - 3.8L and 4.6L (2V) Engines
    Special Tool(s) Clutch Aligner 308-020 (T74P-7137-K) Material Item Specification Premium Long Life Grease XG-1-C ESA-M1C75-B 1. Remove the transmission. 2. CAUTION: Loosen the bolts evenly to prevent clutch pressure plate ...

    Gearshift Rail Bushing
    Special Tool(s) Universal Puller Set 303-DS005 (D80L-100-A) or equivalent Installer, Shift Rail Bushing 308-244 (T96P-7025-F) Slide Hammer 100-001 (T50T-100-A) Disassembly and Assembly 1. Using the special tools, r ...

    Dual-Function Pressure Switch (4.6L)
    The dual-function pressure switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. The dual-function pressure switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold ...