Catalytic Converter - Direct Fit

Replace the direct-fit catalytic converter on a 2015-2020 Ford F-150 with 5.0L Coyote V8 engine, including oxygen sensor removal and heat shield reinstallation.

Warnings

Tools required

Parts

• Direct-fit catalytic converter assembly × 1 — Use OEM specification or 49-state/CARB compliant aftermarket
• Exhaust flange gaskets × 2 — Use OEM specification
• Oxygen sensor (if damaged) × 1 — Motorcraft DY-1333 or equivalent

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Allow exhaust system to cool completely (minimum 2 hours after engine operation)
4. Raise front of vehicle with floor jack and support securely on jack stands at frame rails
5. Spray all exhaust flange bolts, oxygen sensor threads, and hanger bolts with penetrating oil
6. Locate the catalytic converter on the side being serviced (driver or passenger side)
7. Identify heat shield(s) covering the catalytic converter area

Procedure

1. 1

   Remove heat shield(s)
   Remove the heat shield bolts securing the catalytic converter heat shield. The shield may be in multiple sections. Keep track of bolt locations as some may be different lengths. Remove the heat shield and set aside.
   Torque spec

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

   Disconnect upstream oxygen sensor
   Locate the upstream oxygen sensor (pre-cat) on the exhaust pipe before the catalytic converter. Disconnect the electrical connector by pressing the release tab. Using the oxygen sensor socket, turn counterclockwise to remove the sensor. Inspect sensor condition and replace if damaged or contaminated.
   ⚠Oxygen sensor threads are easily damaged. Use only a proper oxygen sensor socket and avoid applying excessive force.
   Torque spec

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

   Disconnect downstream oxygen sensor
   Locate the downstream oxygen sensor (post-cat) on the exhaust pipe after the catalytic converter. Disconnect the electrical connector and remove the sensor using the oxygen sensor socket, turning counterclockwise. Set aside for reinstallation.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
4. 4

   Remove upstream flange connection
   Locate the flange connection between the exhaust manifold and the catalytic converter inlet. Remove the two or three flange bolts/nuts securing this connection. Support the catalytic converter with one hand while removing the final fastener. Separate the flange and remove the old gasket.
   ⚠Support the catalytic converter weight before removing final fasteners to prevent component drop and injury.
   Torque spec

   Manifold Nuts42 Nm (31 lb-ft)
5. 5

   Remove downstream flange connection
   Locate the flange connection between the catalytic converter outlet and the intermediate exhaust pipe. Remove the two or three flange bolts securing this connection. The catalytic converter may now be loose but still supported by hangers.
   Torque spec

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

   Disconnect exhaust hangers
   Identify the rubber exhaust hangers supporting the catalytic converter assembly. These are typically located mid-section on the converter body. Pull down and twist to release the hanger rods from the rubber isolators. If hanger bolts are present, remove them.
   Torque spec

   Hanger Bolts26 Nm (19 lb-ft)
7. 7

   Remove catalytic converter
   With all connections and hangers disconnected, carefully lower and remove the catalytic converter from the vehicle. Maneuver carefully to avoid damaging brake lines, fuel lines, or other components. Remove and discard all old flange gaskets.
   ⚠Catalytic converter is heavy and awkward. Use proper lifting technique or have an assistant help to avoid strain or dropping the component.
8. 8

   Clean mating surfaces
   Using a wire brush, thoroughly clean all flange mating surfaces on both the exhaust manifold outlet and intermediate pipe inlet. Remove all carbon buildup, old gasket material, and corrosion. Wipe clean with a rag.
   ℹ️Clean mating surfaces ensure proper sealing and prevent exhaust leaks.
9. 9

   Install new catalytic converter
   Position new flange gaskets at both the upstream and downstream connections. Maneuver the new catalytic converter into position, aligning the inlet flange with the exhaust manifold outlet and outlet flange with the intermediate pipe. Thread hanger rods into rubber isolators or loosely install hanger bolts if equipped.
   Torque spec

   Hanger Bolts26 Nm (19 lb-ft)
10. 10

    Install upstream flange bolts
    Apply anti-seize compound to the threads of the upstream flange bolts/nuts. Install bolts hand-tight, ensuring the flange gasket remains properly positioned. Torque bolts in a cross-pattern to specification.
    Torque spec

    Manifold Nuts42 Nm (31 lb-ft)
11. 11

    Install downstream flange bolts
    Apply anti-seize compound to the threads of the downstream flange bolts. Install bolts hand-tight, ensuring proper gasket alignment. Torque bolts in a cross-pattern to specification.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
12. 12

    Reinstall oxygen sensors
    Apply a small amount of anti-seize compound to the threads of both oxygen sensors (avoid getting anti-seize on the sensor tip). Install the upstream (pre-cat) oxygen sensor first, threading by hand initially, then torque to specification. Repeat for downstream (post-cat) sensor. Reconnect both electrical connectors ensuring they click securely.
    ⚠Apply anti-seize only to threads, never to the sensor tip. Contamination of the sensor element will cause malfunction.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)
13. 13

    Reinstall heat shield
    Position the heat shield(s) over the catalytic converter in the original configuration. Install all heat shield bolts and torque to specification. Ensure the shield does not contact or rattle against the catalytic converter body.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Double-check that all flange bolts, hanger bolts, and heat shield bolts are properly torqued
2. Verify both oxygen sensor electrical connectors are fully seated and locked
3. Inspect the entire exhaust system for proper clearance from brake lines, fuel lines, driveshaft, and chassis components
4. Ensure all rubber exhaust hangers are properly engaged

Verification

• Lower vehicle from jack stands safely
• Start engine and listen for exhaust leaks at both flange connections. A hissing sound indicates a leak
• With engine at operating temperature, visually inspect all connections for signs of exhaust gas escaping
• Use a scan tool to verify oxygen sensor signals are reading properly (should fluctuate for upstream sensor, should be relatively steady for downstream sensor)
• Check for diagnostic trouble codes (DTCs). Clear any codes present before the repair and verify no new codes appear after a complete drive cycle
• Test drive vehicle and verify normal exhaust sound, no rattles, and check engine light remains off
• After 50-100 miles of driving, re-inspect all flange connections for signs of leaks and verify all fasteners remain tight

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