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 MANUALSFORD2009RANGER 2D PICKUP, 2.3 D, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 15 (EXHAUST SYSTEM)GENERAL PROCEDURESEXHAUST SYSTEM ALIGNMENT - 6.0L DIESEL
2009 Ford Ranger 2D Pickup, 2.3 D, Automatic
Exhaust System Alignment - 6.0L Diesel
2009 Ford Ranger 2D Pickup, 2.3 D, AutomaticSECTION Exhaust System Alignment - 6.0L Diesel
WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
- Loosen all fasteners joining the exhaust system components.
- Beginning at the rear of the vehicle, the exhaust system should be aligned to establish the maximum clearance to its surrounding components. Make sure all fit pipes are pushed all the way into the preceding pipe and the pipe notches are fully seated and correctly lined up with the tabs.
- Tighten the muffler and tailpipe assembly-to-catalytic converter (or if equipped extension pipe) Torca® clamp.
- Tighten to 55 Nm (41 lb-ft).
- If equipped, tighten the extension pipe-to-catalytic converter Torca® clamp.
- Tighten to 55 Nm (41 lb-ft).
- Tighten the exhaust downpipe-to-turbocharger clamp.
- Tighten to 9 Nm (80 lb-in).
- Tighten the exhaust downpipe-to-catalytic converter nuts.
- Tighten to 40 Nm (30 lb-ft).
- Start the engine and check the exhaust system for leaks.
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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.