Ford F150 Pickup. Manual - part 1121

Courtesy of FORD MOTOR CO. 

Fig. 7: Exhaust System Components - Lightning & Harley Davidson Supercab 
Courtesy of FORD MOTOR CO. 

 

2003 Ford Pickup F150 

2003 ENGINE Exhaust - F150 Pickup

  

Fig. 8: Exhaust System Co Exhaust System Components - Harley Davidson SuperCrew 
Courtesy of FORD MOTOR CO. 

DIAGNOSIS & TESTING 

EXHAUST SYSTEM 

Inspection & Verification 

1. Verify the customer's concern by running the engine or road testing the vehicle to duplicate the condition. 

2. Visually inspect for obvious signs of mechanical and electrical damage. Refer to the following chart. 

 

2003 Ford Pickup F150 

2003 ENGINE Exhaust - F150 Pickup

  

Fig. 9: Visual Inspection Chart 
Courtesy of FORD MOTOR CO. 

3. If the fault is not visually evident, determine the symptom and GO to SYMPTOM CHART .  

SYMPTOM CHART 

Fig. 10: Exhaust System Symptom Chart 
Courtesy of FORD MOTOR CO. 

GENERAL PROCEDURES 

EXHAUST SYSTEM ALIGNMENT 

1. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING  

2. Check for loose, damaged, or missing heat shields. Install new heat shields as necessary. Check for any 

trapped debris between the heat shields and the exhaust system components.  

3. Loosen all exhaust component fasteners and clamps from the exhaust manifolds to muffler inlet pipe. 

NOTE:

Make sure the exhaust insulators are hanging straight up and down and 

 

2003 Ford Pickup F150 

2003 ENGINE Exhaust - F150 Pickup

  

4. Beginning at the front of the vehicle, align the exhaust system to establish the maximum clearance. Make 

sure the muffler extension pipe and the muffler inlet pipe are pushed all the way into the preceding pipe 
and the notches are correctly lined up with the tabs.  

5. Beginning at the front of the vehicle, tighten all fasteners and clamps to specification. For additional 

information, refer to SPECIFICATIONS .  

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

REMOVAL & INSTALLATION 

DUAL CONVERTER Y-PIPE - RH & LH 

Removal & Installation 

All Vehicles 

1. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .  

2. Remove the muffler and tail pipe assembly and, if equipped, the muffler extension pipe. 

Vehicles With 4.6L And 5.4L Engines 

3. Disconnect the HO2S and the catalyst monitor sensor. 

are free to move.

NOTE:

To ease the removal and installation of the exhaust components, lubricate the 
insulators using Aerosol Silicone Lubricant F5AZ-19553-AA or equivalent 
meeting Ford Specification ESR-M13P4-A.

NOTE:

On the 4.2L engine, the two upstream Heated Oxygen Sensors (HO2S) are 
located on the exhaust manifolds (9430) and do not need to be removed.

 

2003 Ford Pickup F150 

2003 ENGINE Exhaust - F150 Pickup