Section 09-00: Exhaust System
1996 F-150, F-250, F-350, F-Super Duty, Bronco and Motorhome Chassis Vehicles Workshop Manual
REMOVAL AND INSTALLATION

Exhaust Hanger Insulators

The procedures for removing and installing the various rubber exhaust system supports may be determined by using the removal and installation procedures for the applicable component, the illustrations provided and the torque specifications in this section. Use a soap solution to ease installation of rubber insulators.

Do not use petroleum-based lubricants such as grease or WD-40®.

Exhaust System, Bronco, F-150, F-250, F-350 Regular Cab, SuperCab and Chassis Cab, 4x2 and 4x4, 4.9L SFI and Bronco 5.8L Engines





ItemPart NumberDescription
15F250Catalytic Converter
2375636-S309Nut, Catalytic Converter-to-Exhaust Manifold
3389112-S2Stud, Catalytic Converter-to-Exhaust Manifold
49J454Air Inlet Tube
55230Muffler
6N804034-SClamp
75E287Catalytic Converter Heat Shield, Front
8N605905-S103Bolt, Front Heat Shield
9N803714-S102Nut, U-Lock
10N800295-S102Nut, U-Lock
115K283Catalytic Converter Heat Shield, Rear
125F250Catalytic Converter
13N605905-S1023Bolt, Rear Heat Shield
14N647098-SRivet
155A246Muffler Assembly Bracket
16N620481-S2Nut, Support Bracket
175A212Muffler Extension Pipe
18N803714-S102Nut, U-Lock
ATighten to 34-46 Nm
(25-34 Lb-Ft)
BTighten 40-50 Nm
(30-37 Lb-Ft)
CTighten to 54-71 Nm
(40-52 Lb-Ft)
DTighten to 22-28 Nm
(16-21 Lb-Ft)
ETighten to 17-23 Nm
(13-17 Lb-Ft)


Exhaust System, Bronco, F-150, F-250, F-350, 4.9L, 5.0L and 5.8L Engines Under 8500 GVW





ItemPart NumberDescription
15260Exhaust Outlet Pipe Frame Bracket
25230Muffler
3N605803-S2Bolt
45C226Gasket
5N802641-S2Flag Nut
6N620481-S2Nut
ATighten to 17-23 Nm
(13-17 Lb-Ft)
BTighten to 34-46 Nm
(25-34 Lb-Ft)


Exhaust System, Bronco, F-150, F-250, F-350 Regular Cab and SuperCab, 4x2 and 4x4, 5.0L, 5.8L and Bronco MFI Engine





ItemPart NumberDescription
15F250Catalytic Converter Assembly
2391104-S2Stud, Catalytic Converter-to-Exhaust Manifold
3375636-S309Nut, Catalytic Converter-to-Exhaust Manifold
49J454Air Inlet Tube
5N804034-SClamp
65230Muffler
75E287Catalytic Converter Heat Shield, Front
8N605905-S103Bolt, Front Heat Shield
9N800295-S102Nut, U-Lock
105K283Catalytic Converter Heat Shield, Rear
115F250Catalytic Converter
12N647098-SRivet
135A246Muffler Assembly Bracket
14N620481-S2Nut, Support Bracket
15N803714-S102Nut, U-Lock
ATighten to 40-50 Nm
(30-37 Lb-Ft)
BTighten to 34-46 Nm
(24-34 Lb-Ft)
CTighten to 54-71 Nm
(40-52 Lb-Ft)
DTighten to 22-28 Nm
(16-21 Lb-Ft)
ETighten to 17-23 Nm
(13-17 Lb-Ft)
F5.8L California Only
G5.0L 50 States
5.8L 49 States
(No Air Inlet Tube on
California 5.8L)


Exhaust Systems, F-250, F-350, F-Super Duty Regular Cab, SuperCab and Chassis Cab, 4x2 and 4x4, 5.8L MFI Engine with Manual Transmission, and Chassis Cab with C-6 Automatic Transmission





ItemPart NumberDescription
1391104-S2Stud, 7/16-14-14 x 2.55
2375636-S309Nut, 7/16-14
35246Exhaust Inlet Pipe
45260Exhaust Outlet Pipe Frame Bracket
55260Exhaust Outlet Pipe Frame Bracket
65230Muffler
75277Muffler Pipe Bracket
8W611633-S2Screw, M8-1.25 x 14
9N807703-SU-Bolt Clamp
105E212Catalytic Converter
11N647098-SRivet, M10 x 30
125260Exhaust Outlet Pipe Frame Bracket
13N620481-S2Nut, M8-1.25
145B266Exhaust Converter Inlet Pipe Gasket
15N620482-S2Nut, M10-1.5
AInstall Short Threaded End into Manifold, Tighten to 41-54 Nm (30-40 Lb-Ft)
BTightening Sequence: Tighten RH Nut Halfway, Tighten LH Nut to 34-46 Nm (25-34 Lb-Ft), Tighten RH Nut to 34-46 Nm
(25-34 Lb-Ft)
CAt Assembly, Lubricate Insulators with Lubricant ESE-M99B144-A (5%, 200 Parts Water to 1 Part Lubricant). Do Not Use Oil or Grease.
DModel Dependent
ETighten to 17-23 Nm
(13-17 Lb-Ft)
FTighten to 54-71 Nm
(40-52 Lb-Ft)


Exhaust System, F-250, F-350 5.8L MFI and 7.5L MFI Engine, Manual Transmission, over 8500 GVW





ItemPart NumberDescription
15246Exhaust Inlet Pipe
25F235Air Inlet Tube
35260Exhaust Outlet Pipe Frame Bracket
45A231Muffler Inlet/Outlet Pipe Yoke Clamp
5N623332-S2U-Nut, M6-1.0
6N605892-S2Bolt, M6-1.0 Hex Flange
ATighten to 54-71 Nm
(40-52 Lb-Ft)
BTighten to 50-68 Nm
(37-50 Lb-Ft)


Exhaust System, Typical, F-250, F-350, F-Super Duty Regular Cab, SuperCab and Chassis Cab, 4x2 and 4x4 and 7.5L MFI Engine, over 8500 GVW





ItemPart NumberDescription
15F235Air Inlet Tube
25260Exhaust Outlet Pipe Frame Bracket
35260Exhaust Outlet Pipe Frame Bracket
45230Muffler
55A231Muffler Inlet/Outlet Pipe Yoke Clamp
65246Exhaust Inlet Pipe
75A212Muffler Inlet Pipe
8N647098-SRivet
95260Exhaust Outlet Pipe Frame Bracket
10N620481-S2Nut, Muffler Support
ATighten to 54-71 Nm
(40-52 Lb-Ft)
BTighten to 50-68 Nm
(37-50 Lb-Ft)
CTighten to 17-23 Nm
(13-17 Lb-Ft)


Exhaust System, Typical, F-350 Crew Cab, 4x2 and 4x4, 5.8L MFI, 7.5L MFI (Same as F-350 Except as Shown)





ItemPart NumberDescription
1N620481-S2Nut, Muffler Inlet Pipe Support
25260Exhaust Outlet Pipe Frame Bracket
3N807703-SClamp
45A231Muffler Inlet/Outlet Pipe Yoke Clamp
55A212Muffler Inlet Pipe
ATighten to 54-71 Nm
(40-52 Lb-Ft)
BTighten to 50-68 Nm
(37-50 Lb-Ft)


F-Super Duty Motorhome Chassis Vehicles, 7.5L MFI





ItemPart NumberDescription
19430Exhaust Manifold
2387431Stud, Exhaust Manifold-to-Exhaust Inlet Pipe
3375636-S7Nut, Exhaust Manifold-to-Exhaust Inlet Pipe
45260Exhaust Outlet Pipe Frame Bracket
5N620481-S50Nut, Muffler Inlet Pipe Support
65230Muffler
7605801Bolt, Outlet Pipe Support
8357636-SNut, Outlet Pipe Support
9Heat Shield (Part of 5230)
105260Exhaust Outlet Pipe Frame Bracket
11N807703-SClamp
125246Exhaust Inlet Pipe
135260Exhaust Outlet Pipe Frame Bracket
14N60584Bolt, Muffler Support
15N802641-S2Nut, Muffler Support
ATighten to 41-54 Nm
(30-40 Lb-Ft)
BTighten to 34-46 Nm
(25-34 Lb-Ft)
CTighten to 17-23 Nm
(13-17 Lb-Ft)
DTighten to 54-71 Nm
(40-52 Lb-Ft)
ETighten to 40-60 Nm
(30-44 Lb-Ft)