Crown Victoria V8-4.6L SOHC VIN W (2005)
Disclaimer
Service Procedure
NOTE
TSB EXCLUDES THE FOLLOWING VEHICLES:
FLEX FUEL, NATURAL GAS, AND GULF COAST COUNTRIES (GCC MARKET) VEHICLES.
The following may be required to perform this procedure:
^
Rotunda Exhaust Flaring Tool Part Number 309-002 with instructions sheet
^
Rotunda Template Part Number 536270
1.
Verify the rear catalyst rattle by lightly tapping the rear catalytic converter with a rubber mallet. If the rear catalyst does not rattle do not continue
with this TSB.
NOTE
IF CATALYST HEAT SHIELD IS RATTLING REFER TO SECTION 309-00 OF THE WORK SHOP MANUAL (WSM).
2.
If the rear catalytic converter does rattle disconnect HEGO sensor electrical connector(s).
3.
Remove the HEGO sensor from the exhaust system using tool number 303-476 (T94P-9472-A) or equivalent.
4.
Copy and cut out the template (Rotunda Part Number 536270) from the Rotunda exhaust flaring tool instruction sheet and tape the template to the
exhaust pipe just below the downstream HEGO boss.
NOTE
THE TEMPLATE MUST BE PLACED AGAINST THE HEGO BOSS BASE NOT THE WELD.
(FIGURE 2)
5.
Use a white paint pencil to mark a line around the exhaust pipe at the rear edge of the template. (Figure 2)
NOTE
IN SOME RARE CASES, THE MARK MAY OCCUR SLIGHTLY ONTO THE REAR CATALYST CAN. THIS WILL NOT AFFECT THE
REPAIR BECAUSE THE EXHAUST PIPE EXTENDS INTO THE CATALYST CAN.
6.
Using a reciprocating saw or equivalent tool, cut through the marked line.
NOTE
IT IS VERY IMPORTANT TO MAKE SURE THE CUT IS AS STRAIGHT ACROSS AS POSSIBLE. DO NOT USE A CUTTING TORCH.