'87-96 exhaust systems exploded diagram for 5.0L/5.8L and 4.9L w…

1/2-ton EFI Exhaust
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Before madly ripping out all the emissions systems on your vehicle, read this article.

'95-96 MAF has 2 upstream oxygen sensor bungs; all '96 have one downstream, in addition to any upstream.

'96 Bronco Catalyst-to-Muffler Flange takes obsolete gasket F6TZ-5C226-AB; not available from Ford, NAPA, Advance, CarQuest, O'Reilly, Walker. I used red silicone.

My '95 4.9L uses DY-733.
My '93 5.8L uses Bosch HEGO F1UF-9F472-AA (DY-731), 0 258 003 384, 366 16 90, 3 F 16 (probably the date code: 1993 6th month 16th day).

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Note: It is normal for a certain amount of moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.

** Exhaust System Alignment **

A misaligned exhaust system is usually indicated by vibration, grounding, rattling or binding of system components. Often the associated noise is hard to distinguish from other chassis noises. Look for broken or loose clamps and brackets. Replace or tighten as necessary. It is important that exhaust clearances and alignment be maintained.

Perform the following procedures to align the system:

1. Loosen the retaining hardware, clamp and the pipe support brackets.

2. Align the exhaust system, beginning at the front of the vehicle, to establish maximum clearance.

3. Tighten all retainers to specification. Note: Tighten the flange nuts and the exhaust manifold nuts evenly and alternately.

Note: Three way catalytic converters (TWC) (5E212), exhaust inlet pipes (5246), mufflers (5230), brackets, clamps and insulators should be replaced if they are worn or badly corroded. Do not attempt to service these parts.

4. Start the engine and check the exhaust system for leaks.

** Service fix for Noise: Loose Catalyst or Muffler Heat Shields **

NOTE: At idle or during normal driving conditions, a buzz or rattle may be detected, which can be traced to the exhaust system. The heat shield attachment to the muffler or catalyst may come free. The loose shield will vibrate off the muffler or catalyst and cause the buzz or rattle.

1. Attach two worm clamps (Part #391218 ) to the catalyst or muffler as shown in the illustration. NOTE: The catalyst may have two cans. If shields on both cans are loose, four clamps (2 of each) will be required.

2. Align the clamp to secure the heat shield to the muffler or catalyst. NOTE: Torque the clamp to no more than 68 N-m (60 in-lb).

3. Trim excess band to approximately 25.4mm (1 inch).

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For exhaust leaks, see:

Part of 1980-1986 Ford Bronco Exploded Parts Diagrams

Owner caption July 2012 · Photo 4470 of 6546