How to Replace the Catalytic Converter: 2009-2014 Ford F-150

Watch this video to learn how to replace the catalytic converter on a 2009-2014 Ford F-150.

Replacing the Catalytic Converter on a 2009-2014 Ford F-150: What You Need

Ready to perform this DIY replacement job? Remember that all the parts in this guide can be found on CarParts.com. Check out all the products that fit your vehicle right here.

Parts Checklist

• Catalytic converter: Passenger side and Driver side
• Penetrating oil
• Exhaust sealant
• Grease

Tightening Torques

• Oxygen sensors: 34 Ft-lbs.
• Catalytic converter to Exhaust manifold nuts: 30 Ft-lbs.
• Front driveshaft-to-transfer case flange bolts (4WD models): 41 Ft-lbs.
• Rear driveshaft-to-differential flange bolts (2WD or 4WD models): 76 Ft-lbs.
• Transmission crossmember-to-chassis bolts: 66 Ft-lbs.
• Transmission mount-to-crossmember nuts: 72 Ft-lbs.

Tools Checklist

Here’s the toolbox we recommend to repair your Ford F-150: HM85 85 Piece Ratchet and Socket Set

List of tools:

• Hydraulic jack
• Jack stands
• Wheel lug wrench
• Wire brush
• Marker
• Ratchet x2
• 13mm socket
• 18mm socket
• 15mm socket
• 10mm socket
• Extender X2
• Long 10mm socket
• Hammer
• 15mm wrench
• Flathead screwdriver
• Gimbal
• 22mm wrench
• Torque wrench

Step-by-Step Instructions

Step 1: Initial Preparation

• Turn off ignition, set parking brake, and open hood.
• Raise the front of the vehicle and secure it on jack stands.
• Position yourself under the vehicle.

Step 2: Prepare for Removal

• Apply penetrating oil to screws holding the exhaust line to the catalytic converter.
• Unscrew these screws using a ratchet and 13 mm socket.

Step 3: Remove Metal Crosspiece

• Apply penetrating oil to screws on the metal crosspiece that supports the gearbox.
• Unscrew nuts from gearbox mount using a ratchet and 18 mm socket.
• Use a jack against the transfer case to support gearbox assembly.
• Unscrew nuts from ends of the metal crosspiece using ratchets, 18 mm socket, and 15 mm socket.
• Remove screws and heat shields on the crosspiece using a ratchet and 10 mm socket.
• Remove the metal crosspiece.

Step 4: Gearbox Mount Removal

• Unscrew screws on driver’s side by removing driveshaft.
• Mark driveshaft and unscrew retaining screws on transfer case and front differential sides.
• Tap driveshaft ends to uncouple it.
• Remove the upper silent block retaining screw using a 15 mm wrench.
• Shift driveshaft and unscrew screws holding the gearbox mount on the driver’s side.
• Repeat on the passenger side.

Step 5: Oxygen Sensor Disconnection

• Use a flathead screwdriver to disconnect oxygen sensor connectors on the driver’s side.
• Disconnect oxygen sensor connectors on the passenger side.

Step 6: Remove Catalytic Converters

• Unscrew nuts holding catalytic converters to exhaust manifold using ratchet, large extenders, and 15 mm socket.
• Carefully remove catalytic converters.

Step 7: Prepare New Catalytic Converters

• Install new oxygen sensors using a 22 mm wrench.
• Position passenger-side catalytic converter on exhaust manifold and tighten retaining nuts briefly.
• Apply exhaust sealant to the junction tube and fit the second tube using the holding clamp provided.
• Repeat process for driver’s side catalytic converter.

Step 8: Reassemble Components

• Replace gearbox mount on exhaust line retaining rods and tighten nuts.
• Reconnect oxygen sensors and clip them securely.
• Tighten catalytic converter retaining nuts on exhaust manifold briefly.
• Apply exhaust sealant and tighten screws.
• Tighten holding clamps and catalytic converters using torque wrench.
• Replace gearbox mount retaining screws and tighten nuts with torque wrench.
• Replace upper silent block screw.
• Coat junction between exhaust line and catalytic converter with exhaust sealant and tighten screws.

Step 9: Final Steps

• Tighten holding clamps with a torque wrench.
• Tighten catalytic converters on the exhaust manifold using torque wrench.
• Replace driveshaft and tighten screws with torque wrench.
• Brush and grease metal crosspiece location.
• Replace metal crosspiece and tighten screws with torque wrench.
• Tighten gearbox mount nuts with torque wrench.
• Tighten heat shield retaining screws on metal crosspiece.

Step 10: Complete the Process

• Lower the jack and secure the gearbox assembly on the metal crosspiece.
• Lower the vehicle to the ground.

Compatible Vehicles

The operation and tools displayed in the video should be available on the following vehicles:

• 2009 Ford F150
• 2010 Ford F150
• 2011 Ford F150
• 2012 Ford F150
• 2013 Ford F150
• 2014 Ford F150

Important Reminders

Raise the front of your vehicle high enough, which will allow you to remove the catalytic converter later.

We advise you to have someone help you to hold the catalytic converter assembly in place to prevent it from falling when unscrewing.

Each oxygen sensor has a different cable length. Take the example of the old line so as not to invert the sensors.

Disclaimer:

This video is for entertainment purposes only. Carparts.com, Inc. disclaims all damages including, but not limited to, actual, consequential, and/or punitive, for any liability, claim, or any other injury or cause related to or arising from any information or lack thereof posted in this video. No information contained in this video shall create any expressed or implied warranty or guarantee of any particular result. All mechanical car projects entail some risk. It is the sole responsibility of the viewer to assume this risk. If you are in doubt, please consult a licensed mechanic in your area.