Exhaust System Alignment

All vehicles 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
2. Loosen the muffler assembly-to-intermediate pipe ball clamps.
3. Loosen the Torca® coupler nuts.
   • Do not tighten the coupler at this time.

   Boss® 302 only 

4. NOTE: Do not bend, twist or allow the exhaust side pipes to hang from the flexible bellows or damage to the exhaust side pipe may occur.

   Loosen the exhaust side pipe-to-exhaust H-pipe nuts.

5. Loosen the exhaust side pipe Torca® clamps.

   5.0L and Boss® 302 only 

6. Loosen the catalytic converter-to-exhaust H-pipe ball clamps.

   All vehicles 

7. Loosen the catalytic converter-to-manifold nuts.
   • Do not tighten the coupler at this time.
8. Position an adjustable jackstand under the catalytic converter Y-pipe/H-pipe.
9. Make sure the 3 muffler assembly hooks are correctly inserted into all of the muffler exhaust isolators.
10. Beginning at the front of the vehicle, align the exhaust system in the following sequence.
    1. Evenly tighten all 4 of the catalytic converter-to-exhaust manifold nuts (starting with the right lower, then the left lower, then the right upper, then the left upper) in 10 Nm (89 lb-in) increments until reaching the final torque of 40 Nm (30 lb-ft).
    2. (5.0L and Boss® 302 only) Tighten the catalytic converter-to-exhaust H-pipe ball clamp nuts to 30 Nm (22 lb-ft).
    3. NOTE: Make sure that the intermediate pipe and converter Y-pipe/H-pipe is inserted into the Torca® coupler correctly.