FORD MUSTANG 2003 Workshop Manual

SPECIFICATIONS
SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft Dual converter-
to-exhaust manifold nuts 40 30
Sleeve U-
bolt nuts 55 41
Dual converter-
to-inlet pipe flange nuts 35 26 Klj . 1 ba
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DESCRIPTION AND OPERATION
Exhaust System
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 303 - 14 for
location of the heated oxygen sensors.
The exhaust system:
zcontains dual three- way catalytic converters.
z has a crossover pipe downstream of the three way catalytic converters (4.6L).
z has two upstream heated oxygen sensors mounted before the three- way catalytic converters.
z the production muffler and tailpipe assembly is a one- piece design exhaust system.
Exhaust System — 3.8L Exhaust System — 4.6L (2V) SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Item Part Number Description
1 5F250 Dual converter assembly
2 5D255 Insulator bracket assembly
3 5A246 Insulator bracket, (tailpipe)
4 5D255 Insulator bracket assembly
5 5232 Muffler Klj . 1 ba
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Exhaust System —
4.6L (4V) Item Part Number Description
1 5F250 Dual converter assembly
2 5230 Muffler, RH
3 5260 Insulator bracket assembly, RH
4 5260 Insulator bracket assembly, LH
5 5A246 Insulator bracket, tailpipe (2 req'd)
6 5230 Muffler, LH
Item Part Number Description
1 5F250 Dual converter assembly
2 5230 Muffler, RH
3 5260 Insulator bracket assembly, RH
4 5260 Insulator bracket assembly, LH
5 5230 Muffler, LH Klj . 2 ba
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Klj . 3 ba
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DIAGNOSIS AND TESTING
Exhaust System
Symptom Chart
SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Symptom Chart
Condition
Possible Sources Action
z Noisy or
leaking
exhaust z
Broken or loose
clamps, hangers or
isolators.
z Punctures in the muffler
(5230).
z Broken, loose or
missing exhaust
manifold fasteners or
gaskets.
z Loose heated oxygen
or catalyst monitor
sensor. z
REPAIR as necessary.
z Exhaust system
misalignment. z
ALIGN exhaust system.
z Broken or loose
catalyst internal
components. z
LOOSEN all fasteners joining
the exhaust system and SHAKE
the system to isolate the
concern. REPAIR as necessary.
z Loss of
power z
Kinked or damaged
exhaust pipe.
z Clogged three- way
catalytic converter
(5F250).
z Foreign object in the
exhaust system. z
REPAIR as necessary. Klj . 1 ba
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Klj . 2 ba
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REMOVAL AND INSTALLATION
Muffler —
3.8L
Removal and Installation 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Support the rear axle with a suitable jack.
3. Remove the upper arm- to-differential bolt.
4. Remove the nut and bolt and disconnect the rear shock absorbers (18124) from the axle housing.
zDiscard the nut.
5. Lower the rear axle.
6. Remove the dual converter assembly flange nuts.
SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
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7. Remove the exhaust pipe assembly (5232) from the rear exhaust hanger insulator (5260).
8. Remove the exhaust hanger insulators.
9. Remove the muffler (5230).
10. CAUTION: Do not use oil or grease- based lubricants on insulators as they
deteriorate the rubber.
NOTE: A soap-and- water solution will ease installation of the exhaust hanger insulators.
To install, reverse the removal procedure. Klj . 2 ba
32003 Mustang Workshop Manual
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Klj . 3 ba
32003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Muffler —
4.6L (2V)
Removal and Installation 1. Use a jack to support and lower the rear axle.
2. Remove the upper arm- to-differential bolt.
3. Remove the nut and bolt, and disconnect the rear shock absorbers (18124) from the axle housing.
zDiscard the nut.
4. Lower the rear axle.
5. Remove the dual converter assembly nuts. (RH shown, LH similar.)
6. Remove the RH intermediate exhaust hanger insulator.
SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...