How to Replace a Catalytic Converter on a Ford Windstar

One of the more expensive auto repairs is having to replace the catalytic converter. Unfortunately, this is a very common mechanical component to fail on Ford Windstars. The catalytic converter is an expensive component, and having a mechanic replace it will cost you even more. Luckily, you can save some money and replace it yourself. This guide will walk you through replacing your Ford Windstar catalytic converter.

Directions

1

Gather Your Tools

Before you begin the replacement, you want to make sure that you have all of the tools needed. You will need four jack stands, a car jack, socket set, torque wrench, penetrating oil, and a new catalytic converter. You want to make sure the new converter comes with new gaskets. If not, you will also need new gaskets to complete the repair.

2

Jack Up Your Vehicle

You will need access to the entire catalytic converter assembly. The easiest way to get access is to jack up the entire car. Rest each side of the car on two jack stands. This will allow you access to the underbody of the car and will hold the car securely. Do not simply rest the car on the jack, as this is dangerous.

3

Remove Oxygen Sensor

The first thing that you will need to disconnect is the oxygen sensor. Match the needed socket and then remove it with the torque wrench. The oxygen sensor is an electrical component that monitors your exhaust. After you have disconnected it, you want to strap it up to make sure it is not in your way while you complete the rest of the repair.

4

Apply Penetrating Oil

It is very common for the bolts holding your converter in place to corrode and rust. If this is the case, you will need to apply penetrating oil to loosen them. Let the penetrating oil work for a few minutes. The instructions will tell you how long to leave it.

5

Remove Bolts

Now that the bolts have been loosened, you can remove them using the socket set and torque wrench. You want to loosen all of the bolts, then remove them starting with the back end. After you have removed the back bolts, go ahead and remove the front ones.

6

Remove Catalytic Converter

The catalytic converter should be able to be lifted out of its mount. If it is stuck, you can hit it in the stuck areas with gentle force. It may have some corrosion that is preventing it from being removed.

7

Install New Gaskets

Take the new catalytic converter and install the gaskets. These will seal it and prevent exhaust escaping without being passed through the converter. The new catalytic converter will most likely come with new gaskets. If it does not, make sure that you purchase the correct size.

8

Install New Catalytic Converter

Now that you have prepared the new converter, you are ready to install it. Place it back in the mount, making sure that it is aligned correctly. The converter should have a mark indicating the proper direction to install it. You will need to re-install the bolts and tighten them. Tighten all of the bolts, starting with the front and then moving to the back.

9

Connect Oxygen Sensor

The catalytic converter should now be installed. The next step is to reconnect the oxygen sensor. This is the exact opposite procedure of removing it. Put it back in place and then tighten using the torque wrench and correct-size socket.

10

Test the Repair

The final step is to lower your car from the jack stands and then test the repair. Lower the car one wheel at a time. When this is completed, start the car and monitor the exhaust. You want to make sure that it is not leaking exhaust from the catalytic converter connection. If you see exhaust from this connection, you may have installed the gasket incorrectly.

You can follow this procedure to replace your Ford Windstar catalytic converter. This is a fairly simple repair that should take you about 30 to 45 minutes. It is mainly disconnecting and reconnecting components. You will still need to buy a new catalytic converter, but you will save a large amount of labor costs versus taking your Windstar to a mechanic.