Ford Mustang (1999-2004) Service Manual: Exhaust System Neutralizing

WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area.

NOTE: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded.

1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.

CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can be the cause of a strain problem. Raise and support the vehicle.

2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight.

3. Loosen all exhaust flange joints.

4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress.

5. Tighten the muffler connection.

6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last).

• Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails.
• After neutralization, the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system.
• With the exhaust system installed securely and cooled, the rear hanger should be angled forward.

7. Lower the vehicle.

8. Test the exhaust system for normal operation.