This procedure covers the replacement of a universal catalytic converter on a 2011-2014 Ford F-150 with the 3.5L EcoBoost V6 engine, including removal of exhaust components and oxygen sensors.

Warnings

Tools required

Parts

• Universal catalytic converter × 1 — Must meet EPA/CARB standards for 3.5L EcoBoost
• Exhaust flange gaskets × 2 — Use OEM specification
• Exhaust clamps × 2 — Sized to match pipe diameter
• Oxygen sensor(s) × 1 — Replace if damaged or over 100k miles

Preparation

1. Park vehicle on level ground and allow exhaust system to cool completely (minimum 2 hours)
2. Disconnect negative battery terminal to prevent O2 sensor codes during work
3. Raise vehicle with floor jack and support securely on jack stands at frame rails
4. Spray all exhaust flange bolts, oxygen sensor threads, and hanger bolts with penetrating oil and allow to soak for 15-30 minutes
5. Identify which catalytic converter requires replacement (driver side, passenger side, or both)
6. Take photos of exhaust routing and hanger positions for reference during reassembly

Procedure

1. 1

   Remove heat shields
   Locate and remove the heat shields covering the catalytic converter section. Remove heat shield bolts using appropriate socket. Set shields aside for reinstallation.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
2. 2

   Disconnect oxygen sensors
   Locate the upstream and downstream oxygen sensors on the affected catalytic converter. Disconnect the electrical connectors by pressing release tabs. Using oxygen sensor socket, carefully remove sensors by turning counterclockwise. Apply steady pressure and avoid twisting excessively to prevent sensor breakage. If sensor is seized, apply additional penetrating oil and heat may be required.
   ⚠Do not allow oxygen sensors to hang by their wires. Support the sensor during removal to prevent wire damage.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
3. 3

   Support exhaust system
   Place a jack or exhaust support stand under the exhaust system downstream of the catalytic converter to prevent the system from dropping when disconnected. Position support to maintain alignment during removal.
   ⚠Exhaust system is heavy and will fall if not properly supported. Ensure jack or stand is stable before loosening connections.
4. 4

   Remove downstream flange connection
   Locate the flange connection between the catalytic converter outlet and the downstream exhaust pipe. Remove the flange bolts using appropriate socket. Separate the flange connection and remove the old gasket. Inspect flange surfaces for damage or excessive corrosion.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
5. 5

   Remove upstream flange connection
   Locate the flange connection between the turbocharger downpipe and catalytic converter inlet. Remove the exhaust flange bolts. Carefully separate the connection and remove old gasket. Clean flange surfaces with wire brush to ensure proper sealing during reassembly.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
6. 6

   Disconnect exhaust hangers
   Locate the rubber exhaust hangers supporting the catalytic converter section. Use exhaust hanger tool or pry bar to carefully separate hangers from mounting brackets. Work methodically to avoid tearing rubber hangers.
   ℹ️Lubricating hangers with soapy water makes removal and installation easier.
   Torque spec

   Hanger Bolts23 Nm (17 lb-ft)
7. 7

   Remove catalytic converter
   With all connections and hangers disconnected, carefully lower the failed catalytic converter from the vehicle. Inspect adjacent exhaust components for damage, excessive rust, or cracks that may require attention.
   ⚠Catalytic converter contains precious metals. Properly recycle or return core as required by parts supplier.
8. 8

   Prepare universal catalytic converter
   Measure the inlet and outlet pipe diameters of the original converter. Using reciprocating saw or pipe cutter, cut the universal converter pipes to appropriate length to fit between the existing flange connections. Ensure cuts are straight and perpendicular to pipe axis. Deburr cut edges with file or grinding tool.
   ⚠Wear eye protection when cutting exhaust pipes. Metal shavings and sparks will be produced.
9. 9

   Install universal catalytic converter
   Position the new universal catalytic converter in place, ensuring proper orientation with inlet facing toward engine. Install new exhaust clamps at both inlet and outlet connections. Loosely tighten clamps to allow for final alignment adjustments. Verify adequate clearance from chassis, driveshaft, and fuel lines.
   ⚠Ensure converter orientation matches flow direction arrow on converter body. Reverse installation will cause performance issues.
10. 10

    Reconnect exhaust hangers
    Attach rubber exhaust hangers to mounting brackets. Ensure exhaust system sits at proper height and position before fully tightening connections. Torque hanger bolts to specification.
    Torque spec

    Hanger Bolts23 Nm (17 lb-ft)
11. 11

    Install oxygen sensors
    Apply anti-seize compound to oxygen sensor threads only, keeping compound away from sensor tip. Install sensors into bungs on new catalytic converter, hand-threading first to avoid cross-threading. Torque oxygen sensors to specification using oxygen sensor socket. Reconnect electrical connectors ensuring positive engagement.
    ⚠Never apply anti-seize to oxygen sensor tip or connector area. Contamination will cause sensor failure.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)
12. 12

    Tighten all exhaust connections
    Working from front to rear, tighten all exhaust clamps evenly. If using flanged connections with universal converter adapters, install new gaskets with anti-seize on bolts and torque to specification. Verify all connections are secure and properly aligned.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
13. 13

    Reinstall heat shields
    Position heat shields over catalytic converter assembly. Install and torque heat shield bolts to specification. Ensure shields are properly seated and not contacting moving components.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Reconnect negative battery terminal
2. Double-check all exhaust connections, hangers, and clamps are properly secured
3. Verify adequate clearance between exhaust system and chassis, driveshaft, fuel lines, and brake lines throughout full suspension travel
4. Ensure no tools or parts were left in the work area

Verification

• Start engine and listen for exhaust leaks at all connection points. A hissing sound indicates a leak requiring attention
• Allow engine to reach operating temperature and verify no unusual odors or smoke from exhaust system
• Check for exhaust leaks using soapy water solution at all connections while engine is running
• Perform test drive and verify normal engine performance with no loss of power or unusual sounds
• After test drive, re-inspect all connections and clamps for proper tightness and check for any signs of leaks or movement
• Use OBD-II scanner to verify no catalytic converter efficiency codes (P0420/P0430) or oxygen sensor codes are present
• Monitor check engine light for several drive cycles to ensure catalytic converter is functioning properly

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