Section 09-00: Exhaust System
1996 F-150, F-250, F-350, F-Super Duty, Bronco and Motorhome Chassis Vehicles Workshop Manual
REMOVAL AND INSTALLATION

Exhaust Inlet Pipes, DI Turbo Diesel Engine

Removal

  1. Remove the bolts and nuts retaining the exhaust inlet pipes to exhaust manifolds (9430).

  1. Remove turbocharger (9G438). Refer to Section 03-04E.

  1. Remove exhaust inlet pipes.





Installation

  1. Install the exhaust inlet pipes to the exhaust manifolds.

  1. Install the turbocharger. Refer to Section 03-04E.

  1. Install bolts and nuts retaining the exhaust inlet pipes to the exhaust manifolds.



Exhaust System Installation, 7.3L DI Turbo Diesel Engine





ItemPart NumberDescription
15230Muffler
25E212Catalytic Converter
36N646Engine Exhaust Charge Pipe
45277Muffler Pipe Bracket
5N620482-S2Nut, M10-1.5
6382802-S2Nut, 3/8-16
75A231Muffler Inlet/Outlet Pipe Yoke Clamp
A—Exhaust System Must Be Held in a Neutral Position During Assembly
B—Use 1 Part Lubricant ESE-M99B144-A in 200 Parts Water to Facilitate Assembly of Exhaust Bracket and Insulator Assemblies. Do Not Use Oil or Grease-Based Lubricants.
C—Tighten to 34-46 Nm
(26-34 Lb-Ft)
D—Tighten to 9-11 Nm
(80-97 Lb-In)


Exhaust System Installation, 7.3L DI Turbo Diesel Engine, Continued





ItemPart NumberDescription
1N647098-SRivet, M10-30
25260Exhaust Outlet Pipe Frame Bracket
35230Muffler
4N620481-S2Nut, M8-1.25
55260Exhaust Outlet Pipe Frame Bracket
65260Exhaust Outlet Pipe Frame Bracket
75A231Muffler Inlet/Outlet Pipe Yoke Clamp
85E212Catalytic Converter
95A212Muffler Extension Pipe
A—Use 1 Part Lubricant ESE-M99B144-A in 200 Parts Water to Facilitate Assembly of Exhaust Bracket and Insulator Assemblies. Do Not Use Oil or Grease-Based Lubricants.
B—Exhaust System Must Be Held in a Neutral Position During Assembly.
C—Tighten to 17-23 Nm
(13-17 Lb-Ft)
D—Model Dependent
E—Tighten to 54-71 Nm
(40-52 Lb-Ft)