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Old 04-28-2018, 03:09 PM   #11
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Job done. The manifold / cat assy. came out the top as expected albeit not as easily as I'd have liked. The heat shroud is the biggest hindrance to pulling it straight out, it's a tight fit to say the least, it took 15 minutes of wiggling, twisting and prying but we prevailed. The whole job took around 2.5 hours, that included welding in the new piece of flex.
Thanks again for the valuable advise.
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Last edited by alconafocusguy; 04-28-2018 at 03:14 PM.
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Old 04-28-2018, 09:58 PM   #12
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Quote:
Originally Posted by alconafocusguy View Post
...The whole job took around 2.5 hours, that included welding in the new piece of flex....
So, minus the welding, that means I should be able to do that job also, in about 7.5 hours. This is a Marde moves way too slow; usually a factor of two or three.

Congrats on the fix. Good job.
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Old 04-29-2018, 12:42 AM   #13
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Great glad you got it swapped out....
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Old 05-04-2019, 07:35 PM   #14
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Exhaust Manifold Stuck

We have a 2005 ZX4 SES 2.0 Duratec with a broken flex pipe. It has a mani-cat with the exhaust manifold, catalytic converter, and flex all 1 piece. I have everything disconnect and the assembly is loose but I can't figure out how to pull it up and out from under the hood. Doesn't seem like there is enough room/clearance. I have not removed AC lines or heater hoses. Do I need to remove motor mounts to loose/move the motor to make room to pull this up and out? What am I missing?

ANSWER: I set out this morning and removed both driver and passenger side upper motor mounts. That gave me just enough movement. I let the manifold lower back towards the firewall and then I was able to pull the manifold heat shield off. Once that was out of the way the mani-cat lifted right out.
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Last edited by Fordfool; 05-05-2019 at 05:19 PM. Reason: Answered own question
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Old 05-06-2019, 01:56 AM   #15
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Quote:
Originally Posted by Fordfool View Post
We have a 2005 ZX4 SES 2.0 Duratec with a broken flex pipe. It has a mani-cat with the exhaust manifold, catalytic converter, and flex all 1 piece. I have everything disconnect and the assembly is loose but I can't figure out how to pull it up and out from under the hood. Doesn't seem like there is enough room/clearance. I have not removed AC lines or heater hoses. Do I need to remove motor mounts to loose/move the motor to make room to pull this up and out? What am I missing?

ANSWER: I set out this morning and removed both driver and passenger side upper motor mounts. That gave me just enough movement. I let the manifold lower back towards the firewall and then I was able to pull the manifold heat shield off. Once that was out of the way the mani-cat lifted right out.
Thank you for sharing your method, to remove the mani-cat out thru the top side.

I would caution all others to remember "engine weight support" while these two top engine mounts are removed (the lower engine mount also? -aka dogbone) AND while you move & shift the engine forward to gain space to lift the exhaust manifold (main-cat) out from the car at the firewall side.

This makes me wonder if I can use your method in my 2004 2.3 PZEV if I ever need this mani-cat replacement.

Great to see a first time poster with helpful advice. Thank you.
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