2002 Ford ThunderbirdFACTORY OEM SERVICE PROCEDURE

Exhaust System Alignment

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING article.
  2. Loosen all fasteners joining the exhaust system components.
  3. Beginning at the front of the vehicle, align the exhaust system to establish the maximum clearance. Make sure all fit pipes are pushed all the way into the preceding pipe and the notches are correctly lined up with the tabs.
  4. Beginning at the front of the vehicle, tighten all fasteners and clamps to specification. For additional information, refer to SPECIFICATIONS  in this service information.
  5. Start the engine and check the exhaust system for leaks.
Factory Service Tools

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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.

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