The AllData instructions more closely resemble the factory worksop manual
instructions than do the Haynes instructions.
Some points to ponder.... by and large, the factory manuals assume that you
have a certain amount of prior knowledge and experience... this is not an
insult - it is merely a statement of fact - and I know many adequate techs
that can get caught up in manual procedures and get into trouble...
"adequate" techs. These sorts of problems can compound themselves when you
are stuck working on your back on the floor BTDTGTTS.
FWIW, all of the GOOD techs I know will assess an unfamiliar job and
reassess it as it progresses... even to the point of choreographing some
moves before committing to them.
Work with care and purpose and remember to think ahead to your next move(s)
and you should be OK...
Vehicle: 2002 Ford Taurus V6-3.0L VIN U
Removing & Reinstalling the Dual converter Y-pipe (Haynes Repair
Note: The exhaust headpipe on these cars is a welded assembly of two
catalytic converters and the headpipes for both banks of the engine.
The manufacturer calls it the “dual converter Y-pipe,” or simply the Y-
pipe. The Y-pipe assembly must be removed for other service work, such
as oil pan removal. Refer to Chapter 6 for more information about the
1. Raise the vehicle and support it on jack stands.
2. Disconnect the wiring connectors from the four exhaust oxygen (02)
sensors. 02 sensors are installed upstream and downstream from both
3. Remove the 02 sensors from the headpipes as follows to get the Y-
pipe assembly out of the car: (a) On a Vulcan V6 engine, remove the
upstream 02 sensors from each headpipe, just below each exhaust
manifold; the downstream sensors can stay in place. (b) On a Duratec
V6 engine, remove all four 02 sensors.
4. Remove the nuts that secure the front and rear headpipes to the
exhaust manifold studs.
5. Remove the nuts and bolts from the catalytic converter brackets at
6. Remove the nuts and bolts at the flange connection of the Y-pipe
assembly to the exhaust system flex tube.
7. Remove the Y-pipe assembly from the car. You may want an assistant
to help you because the pipe assembly is heavy and awkward.
8. Install new gaskets at all exhaust system joints during
reinstallation. If the nuts and bolts are corroded, it's a good idea
to replace them also.
9. Install the rest of the parts in the reverse order of removal.
Start the engine, and check for exhaust leaks.
Service and Repair: Dual Converter Y-Pipe (Alldata)
1. Disconnect the negative battery cable.
2. Remove the bolts and engine roll restrictor.
3. Remove the bolt, ground strap, and nut.
4. Raise and support the vehicle.
5. Remove the splash shield and the air deflector.
6. Disconnect the Catalyst Monitor Sensor (CMS) electrical
7. Remove the nuts securing the heat shield and position it out of the
NOTE: Support the exhaust with mechanic's wire.
8. Remove the nuts and disconnect the three-way catalytic converter
from the dual converter y-pipe.
9. Lower the vehicle.
10. Remove the nuts and the bolt.
11. Using the special tools, raise the front of the engine.
12. Raise the vehicle.
13. Remove the bolt.
CAUTION: The sharp edges on the converter can cut the CV joint boot.
Make sure to protect the halfshaft boot with a suitable covering
before removing the converter assembly. Remove the dual Y-pipe
14. Remove the gaskets and, if necessary, the Catalyst Monitor Sensors
(CMS); discard the gaskets.
1. Install the new gaskets and, if removed, install the Catalyst
Monitor Sensors (CMS).
2. Position the dual converter Y-pipe and loosely start the front nuts
and the rear bolt.
3. Tighten the bolt.
4. Lower the vehicle.
5. Tighten the nuts.
6. Lower the engine and remove the special tools.
7. Tighten the bolt.
8. Install the engine roll restrictor and tighten the bolts.
9. Position the heat shield. Install the ground strap and tighten the
bolt and nut.
10. Raise the vehicle.
11. Tighten the nuts.
12. Connect the three-way converter to the dual converter Y-pipe, and
tighten the nuts.
13. Connect the CMS electrical connectors.
14. Install the splash shield and the air deflector, and tighten the
15. Lower the vehicle.
16. Connect the battery cable.