See Figures 1 through 26
REMOVAL & INSTALLATION
When working on exhaust systems, ALWAYS wear protective goggles! Avoid working on a hot exhaust system!
Fig. Fig. 1: 1976-77 F-250 & 350 6-300 crew cab
Fig. Fig. 2: 1976-77 F-100 6-300
Fig. Fig. 3: 1976-77 F-150 & 250 6-300
Fig. Fig. 4: 1976-77 F-100 6-300 Super Cab with shields
Fig. Fig. 5: 1976-77 F-150 & 250 2-wd w/8-390 or 460
Fig. Fig. 6: 1978 6-300 light truck exhaust systems
Fig. Fig. 7: 1979 V8 light truck exhaust systems
Fig. Fig. 8: 1980-83 F-100, 150, 250 (exc. Chassis Cab), 350 6-300
Fig. Fig. 9: 1980-83 Bronco 6-300
Fig. Fig. 10: 1980-83 F-100, 150, 250, 350 V6 and V8 with Catalytic Converter, except California
Fig. Fig. 11: 1980-83 F-Series V8 without Catalytic Converter
Fig. Fig. 12: 1980-83 Bronco V8, except California
Fig. Fig. 13: 1980-83 California Bronco V8
Fig. Fig. 14: 1984 Bronco w/6-300
Fig. Fig. 15: 1984 F-Series w/8-302 or 351W, w/Catalytic Converter, exc. California
Fig. Fig. 16: 1984 F-Series w/8-302 or 351W, without Catalytic Converter
Fig. Fig. 17: 1984 Bronco V8 without Catalytic Converter
Fig. Fig. 18: 1984 Bronco V8 with Catalytic Converter
Fig. Fig. 19: 1984 F-250, 350 diesel
Fig. Fig. 20: 1984 F-Series with 8-460
Fig. Fig. 21: 1985-86 Bronco w/6-300
Fig. Fig. 22: 1985-86 F-Series w/8-302 or 351W, with dual underbody Catalytic Converters and light-off converter w/MTA
Fig. Fig. 23: 1985-86 F-Series w/8-302 or 351W, without Catalytic Converter
Fig. Fig. 24: 1985-86 Bronco V8 with Catalytic Converter
Fig. Fig. 25: 1985-86 F-Series diesel
Fig. Fig. 26: 1985-86 F-Series w/8-460
The following applies to exhaust systems using clamped joints. Some models, use welded joints at the muffler. These joints will, of course, have to be cut.
Raise and support the truck on jackstands.
Remove the U-clamps securing the muffler and outlet pipe.
Disconnect the muffler and outlet pipe bracket and insulator assemblies.
Remove the muffler and outlet pipe assembly. It may be necessary to heat the joints to get the parts to come off. Special tools are available to aid in breaking loose the joints.
On Super Cab and Crew Cab models, remove the extension pipe.
Disconnect the catalytic converter bracket and insulator assembly.
For rod and insulator type hangers, apply a soap solution to the insulator surface and rod ends to allow easier removal of the insulator from the rod end. Don't use oil-based or silicone-based solutions since they will allow the insulator to slip back off once it's installed.
Remove the catalytic converter.
On models with Managed Thermactor Air, disconnect the MTA tube assembly.
Remove the inlet pipe assembly.
Install the components making sure that all the components in the system are properly aligned before tightening any fasteners. Make sure all tabs are indexed and all parts are clear of surrounding body panels. See the accompanying illustrations for proper clearances and alignment. Observe the following torque specifications:
Inlet pipe-to-manifold: 35 ft. lbs.
MTA U-bolt: 60-96 inch lbs.
Inlet pipe or converter-to-muffler or extension: 45 ft. lbs.
Hanger bracket and insulator-to-frame: 24 ft. lbs.
Bracket and insulator-to-exhaust: 15 ft. lbs.
Flat flange bolts (8-460 and diesel) 30 ft. lbs.