Ford Falcon. Manual — part 287

309-00-6 Exhaust

System 309-00-6

REMOVAL AND INSTALLATION

All Rear Muffler Assemblies

6 Cylinder Catalyst Assembly

Removal and Installation

Removal and Installation
1. Remove nuts connecting catalyst assembly to

WARNING: Care must be taken so as to avoid

manifold.

damage to exhaust system & fuel tank heat

NOTE: Manifold studs and mating exhaust nuts

shields. If shields are damaged or substantially

are one time use parts only and must be

distorted they should be replaced, and the fuel

replaced.

tank inspected for damage.

2. Remove bolts connecting intermediate muffler to

1. Remove the nuts connecting the intermediate

catalyst assembly. Discard the gasket.

muffler assembly to the rear muffler assembly.

Discard the gasket.

NOTE: The bolts connecting the intermediate

muffler to the catalyst assembly are of a

2. Disconnect rear muffler assembly from the

self-threading type that have been used to tap

hangers at the front and rear of the muffler and

thread directly into the catalyst assembly outlet

remove by pushing muffler rearward and gently

pipe flange. Conventional class 10.0 bolts with

moving ’over-axle pipe’ through cavity above IRS

similar geometry can be used in place of these

(sedan only).

self-threading bolts.

3. Installation is the reverse of the removal

procedure.

3. Disconnect the catalyst assembly from the hanger

on the outlet pipe and remove.

NOTE: Install new gaskets at each point.

4. Installation is the reverse of the removal

NOTE: Assembly is the reverse of the removal

procedure.

procedure. To ease reattachment of rubber

NOTE: Care must be taken when attaching a

isolators to hanger brackets, a mild detergent

catalyst assembly to a manifold such that it is

solution can be applied to the bracket.

correctly aligned. To achieve this, firstly do up the

NOTE: Care must be taken when attaching a

nuts by hand as far as possible (using a socket

catalyst assembly to a manifold such that it is

with extension), and then torque the nuts up in

correctly aligned. To achieve this, firstly do up the

steps alternating between the two until the

nuts by hand as far as possible (using a socket

nominal torque is achieved.

with extension), and then torque the nuts up in

steps alternating between the two until the

8 Cylinder Catalyst Assemblies (LHS &

nominal torque is achieved.

RHS)

NOTE: Upon conclusion of assembly, system

should be checked for leaks and correct

Removal and Installation

alignment, refer Sections on Diagnosis and

1. Remove nuts connecting catalyst assembly to

Testing and General Procedures.

manifold. Both sides will require the removal of an

additional nut retaining a heat shield.

All Intermediate Muffler Assemblies

NOTE: Manifold studs and mating exhaust nuts

are one time use parts only and must be

Removal and Installation

replaced.

1. Remove bolts connecting intermediate muffler to

catalyst assembly (6 cylinder) or Y-pipe assembly 2. Remove nuts connecting Y-pipe to catalyst

(8 cylinder). Discard the gasket.

assembly. Discard the gasket(s).

NOTE: The bolts connecting the intermediate

3. Disconnect catalyst assembly from the hanger on

muffler to the catalyst/Y-pipe assemblies are of a

the outlet pipe and remove.

self-threading type that have been used to tap

4. Installation is the reverse of the removal

thread directly into the catalyst assembly outlet

procedure.

pipe flange (6 cylinder) or directly into weld nuts

NOTE: Care must be taken when attaching a

on the Y-pipe outlet flange (8 cylinder).

catalyst assembly to a manifold such that it is

Conventional class 10.0 bolts with similar

correctly aligned. To achieve this, firstly do up the

geometry can be used in place of these

nuts by hand as far as possible (using a socket

self-threading bolts.

with extension), and then torque the nuts up in

2. Remove the nuts connecting the intermediate

steps alternating between the two until the

muffler assembly to the rear muffler assembly.

nominal torque is achieved.

Discard the gasket.

3. Disconnect intermediate muffler assembly from

the hanger on the outlet pipe and remove.

4. Installation is the reverse of the removal

procedure.

G56318 en

309-00-7 Exhaust

System 309-00-7

REMOVAL AND INSTALLATION (Continued)

8 Cylinder Y — Pipe Assemblies

Removal and Installation
1. Remove nuts connecting Y-pipe to catalyst

assembly. Discard the gasket(s), and nuts.

2. Remove bolts connecting intermediate muffler to

Y-pipe assembly. Discard the gasket.
NOTE: The bolts connecting the intermediate

muffler to the catalyst assembly are of a

self-threading type that have been used to tap

thread directly into weld nuts on the Y-pipe

assembly outlet flange. Conventional class 10.0

bolts with similar geometry can be used in place

of these self-threading bolts.

3. Remove the Y-pipe assembly.
4. Installation is the reverse of the removal

procedure.

System Diagrams

Sedan - 6 cylinder (ULP)

Item

Description

Item

Description

6

Rubber exhaust hanger insulators

1

M10 Nut assembly

7

Nut assembly

2

Three-way catalytic converter

3

Intermediate muffler assembly

4

Nut Assembly

5

Rear muffler assembly

G56320 en

309-00-8 Exhaust

System 309-00-8

REMOVAL AND INSTALLATION (Continued)

Sedan - 8 cylinder (ULP)

Item

Description

1

M10 Nut assembly

2

Three-way catalytic converter

3

Two-way adapter

4

Intermediate muffler assembly

5

Nut Assembly

6

Rear muffler assembly

7

Rubber exhaust hanger insulators

8

Nut assembly

G56320 en

309-00-9 Exhaust

System 309-00-9

REMOVAL AND INSTALLATION (Continued)

Sedan - 6 cylinder (SFLPG)

Item

Description

1

M10 Nut assembly

2

Three-way catalytic converter

3

Intermediate muffler assembly

4

Nut assembly

5

Rubber exhaust hanger insulators

6

Rear muffler assembly

7

Nut assembly

G56320 en