Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSFORD1996AEROSTAR 2WD V6-182 3.0LREPAIR AND DIAGNOSISENGINE, COOLING AND EXHAUSTEXHAUST SYSTEMCATALYTIC CONVERTERSERVICE AND REPAIR
1996 Ford Aerostar 2WD V6-182 3.0L
Catalytic Converter: Service and Repair
1996 Ford Aerostar 2WD V6-182 3.0LSECTION Service and Repair
REMOVAL
1. Remove the two nuts and two bolts from exhaust pipe flange hold down spring attaching three way catalytic converter to muffler and muffler outlet pipe.
2. Loosen and remove the three nuts that connect the three way catalytic converter to dual converter Y pipe . Swing the muffler and muffler outlet pipe to the rear, and then remove the three way catalytic converter and exhaust converter outlet gaskets, disengaging rod from insulator.
3. Loosen and remove the exhaust manifold-to-inlet pipe bolts. Move the inlet pipe rearward, rotate to clear studs and remove.
INSTALLATION
1. Install exhaust inlet pipe onto exhaust manifold and loosely secure in place with retaining bolts.
2. Position three way catalytic converter in place, engaging rod into insulator.
3. Install a new exhaust converter outlet gasket between the three way catalytic converter and muffler. Secure the flange gasket and flanges with two bolts exhaust pipe flange hold down spring and two nuts. Tighten to 34-46 Nm (25-34 lb ft).
4. Install an exhaust converter inlet pipe gasket between the three way catalytic converter and dual converter Y pipe. Secure with three nuts and tighten to 34-46 Nm (25-34 lb ft).
5. Tighten exhaust manifold connections by alternately tightening the manifold nuts to 34-46 Nm (25-34 lb ft).
1. Remove the two nuts and two bolts from exhaust pipe flange hold down spring attaching three way catalytic converter to muffler and muffler outlet pipe.
2. Loosen and remove the three nuts that connect the three way catalytic converter to dual converter Y pipe . Swing the muffler and muffler outlet pipe to the rear, and then remove the three way catalytic converter and exhaust converter outlet gaskets, disengaging rod from insulator.
3. Loosen and remove the exhaust manifold-to-inlet pipe bolts. Move the inlet pipe rearward, rotate to clear studs and remove.
INSTALLATION
1. Install exhaust inlet pipe onto exhaust manifold and loosely secure in place with retaining bolts.
2. Position three way catalytic converter in place, engaging rod into insulator.
3. Install a new exhaust converter outlet gasket between the three way catalytic converter and muffler. Secure the flange gasket and flanges with two bolts exhaust pipe flange hold down spring and two nuts. Tighten to 34-46 Nm (25-34 lb ft).
4. Install an exhaust converter inlet pipe gasket between the three way catalytic converter and dual converter Y pipe. Secure with three nuts and tighten to 34-46 Nm (25-34 lb ft).
5. Tighten exhaust manifold connections by alternately tightening the manifold nuts to 34-46 Nm (25-34 lb ft).
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.