Section 09-00: Exhaust System | 1996 F-150, F-250, F-350, F-Super Duty, Bronco and Motorhome Chassis Vehicles Workshop Manual |
Perform the following procedures to align the complete exhaust system:
Loosen the pipe connection clamps and the muffler pipe bracket clamps. Loosen the flange-to-exhaust manifold nuts.
Work from the front and progressively align the exhaust system components and exhaust outlet pipe frame brackets (5260) to eliminate any interferences. Make sure that aligning tabs (if used) are fully engaged in their mating slots.
Then, working from the rear forward, retighten clamps to specifications. Finally, tighten the flange-to-exhaust manifold nuts alternately and equally to specifications so that the pressure on the ball flange will be uniform.
Noise, Loose Catalytic Converter or Muffler Heat Shields
NOTE: While idling or during normal driving conditions, a buzz or rattle may be detected, which can be traced to the exhaust system. The heat shield attachment to the muffler (5230) or catalytic converter may come free. The loose heat shield will vibrate off the muffler or catalytic converter and cause the buzz or rattle.
Diagnosis and Repair
NOTE: The catalytic converter may have two cans. If shields on both cans are loose, four clamps (two for each) will be required.
Attach two band clamps (Part No. 383735-S) to the catalytic converter or muffler as shown. Tighten to 7 Nm (60 lb-in).
Align the clamp to secure the heat shield to the muffler or catalytic converter. Tighten the clamp to no more than 7 Nm (60 lb-in).
Trim excess "ear" to approximately 25mm (1 inch).