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How to Install a New Catalytic Converter for Ford Contours

This is not to say that a backyard mechanic couldnt successfully install a new catalytic converter laying on his back underneath a Ford Contour. Its not going to be fun or pretty. There are different designs in the Ford Contour and different motors. Each type will dictate where the catalytic converter is located and determine the degree of difficulty to remove and replace the old one. Some Contours have more than one converter so assuming which type your car is and what it needs will be up to you.

Instructions

1

Lift the Contour on a lift all the way to the top. Load all the tools and new converter into the tool tray and bring it over near you, but keep it out of the way. Put on the safety glasses and locate the converter and determine what youre going to need and where youre going to start.

2

Start with the front of the converter, closest to the motor. If it is attached to the manifold, set up the pneumatic gun, extension, swivel, and the correct sized socket before lighting the torch. Make sure the gun is set to reverse.

3

Light the torch and heat up the manifold stud nuts and when theyre cherry red, turn off the torch, put the gun and socket on the nut and remove it. Repeat this for all the remaining nuts. If the converter is flanged to a front pipe and not the manifold, light the torch and cut the nuts and bolts out of the flange to separate the connection.

4

Cut the rear bolts of the catalytic converter flange connection to the center exhaust pipe with the torch. Again, cutting the bolts from the converter side of the flange connection. Cut the bolts flush or inverted into the flange and turn the torch off. You will be able to knock the remaining bolt through the rest of the flange connection with a hammer and punch if its cut correctly.

5

Remove the old converter and install the new one. Again, start from the front of the Contour to connect the converter and work your way back. It might be wise to allow the exhaust components heated up by the torch to cool down before proceeding. If the converter attached to the manifold place it up onto the studs with the gasket in between and thread on the new manifold stud nuts hand tight. Then re-tighten with the pneumatic gun, swivel, and socket. If it flange connected to a front pipe, place the gasket between the flanges and replace the hardware.

6

Bolt and flat washer on one side of the flange connection and lockwasher and nut on the other side. Tighten the nuts to the bolts with the gun and socket on the nut end and hold the bolt head with a hand wrench.

7

Attach the rear flange connection of the catalytic converter to the center exhaust pipe flange and replace the hardware in the same manner and tighten. If the outlet of the converter is clamp connected to the center pipe, you may need to expand the center pipe (or converter depending on whether it fit over or into the pipe) with a pipe expander

8

Replace the clamp and tighten with the gun and a socket. Once the converter is connected and tightened on both ends, it may be wise to lower the vehicle on the lift, start it up, and raise it back up just to check for any possible leaks coming from the flange or clamp connections.

Posted by Unknown at 1:15 AM

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