Exhaust System - Catalytic Converter Flange Separation
TSB 11-4-1004/27/11
CATALYTIC CONVERTER FLANGE - SERVICE KIT
FORD:
2004-2007 Taurus
MERCURY:
2004-2005 Sable
This article supersedes TSB 09-2-10 to update the vehicle model years.
ISSUE
Some 2004-2007 Taurus vehicles built on or after 12/1/2003 and 2004-2005 Sable vehicles may experience separation of the exhaust flange from the catalytic converter flex coupling. This may occur due to normal component corrosion and stress. A service kit is now available for replacing the flange and flex coupling instead of replacing the entire underbody catalytic converter assembly.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Remove the (separated) catalytic converter flange at the Y-pipe and discard the flange, gasket and attaching nuts.
2. Support the exhaust system at the catalytic converter using a suitable jack stand.
3. Measure and mark the catalytic converter tube 4-15/16" (125 mm) from the rear edge of the flex coupling. (Figure 1)
4. Using a reciprocating saw or equivalent, cut through the marked line to remove the flex coupling, then discard it.
5. De-burr the inner and outer cut edges of the pipe.
NOTE
BE SURE TO REMOVE ANY WASTE/FOREIGN MATERIAL FROM INSIDE THE PIPE TO PREVENT INTERNAL DAMAGE/FAILURE OF THE CATALYTIC CONVERTER.
6. Clean any dirt, rust or corrosion from the outside of the pipe to ensure the service coupling will slip over the tube.
NOTE
BE SURE TO REMOVE ANY WASTE/FOREIGN MATERIAL FROM INSIDE THE PIPE TO PREVENT INTERNAL DAMAGE/FAILURE OF THE CATALYTIC CONVERTER.
7. Measure and make a reference mark on the pipe 2" (50 mm) from the cut edge. (Figure 2)
8. Install the service coupling onto the pipe with the clamp fastener nuts located towards the center of the vehicle. Ensure the service flange is correctly oriented to the Y-pipe flange, and the service coupling is installed to the 2" (50 mm) reference mark on the pipe. (Figure 3)
9. Using a new gasket and nuts install the service coupling/flange to the Y-pipe flange. Torque to 30 lb-ft (40 N.m).
10. Torque the service tube clamp fastener nuts to 33 lb-ft (45 N.m).
NOTE
ENSURE THE SERVICE TUBE IS WITHIN 1/4" (5 MM) OF THE 2" (50 MM) REFERENCE MARK ON THE PIPE BEFORE TORQUING THE CLAMP FASTENER NUTS.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
110410A 2004-2007 Taurus, 0.7 Hr.
2004-2005 Sable 3.0L 2V:
Install The Catalytic
Converter Flange Service
Kit Following Service
Procedure (Do Not Use
With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
5E212 01
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