Below are some parts diagrams and other notes about crown victoria exhaust systems that you may find useful.:
Below are some parts diagrams for original equipment ford exhaust system service parts that can be purchased at your local ford dealer:







Exhaust Manifolds

Part Number
From
To
Side
Comments
Suggested Retail
Legacy Part Numbers
F1AZ-9430-B
1992
1994
RH

Obsolete
F1AZ-9430-A
F1AZ-9431-B 1992
1994
LH

Obsolete
F1AZ-9431-A







F5AZ-9430-A 1995
2002
RH

$168.32 F4AZ-9430-B
F5AZ-9431-A 1995
2002
LH

$206.65 F4AZ-9431-B







4W7Z-9430-AA
2003
2010
RH

$111.65 3W7Z-9430-AA
4W7Z-9431-AA 2003
2010
LH

$94.98 3W7Z-9431-AA
3W7Z-9431-AB

Notes:

Exhaust Manifold -> Cylinder Head Gaskets

Part Number
From
To
Comments
Legacy Part Numbers
YC2Z-9448-A
1995
2010
Exhaust Manifold->Cylinder Head Gasket
One Piece (2 Ports)
F4SZ-9448-A
F4SZ-9448-B
F5AZ-9448-B
F7UZ-9448-AA
F7UZ-9448-CA
F8AZ-9448-AA
F81Z-9448-AA
XW7Z-9448-AA
XW7Z-9448-BA
YC2Z-9448-BA
YC2Z-9448-CA

Some of the exhaust manifold gaskets used to be a one piece unit that covered the 4 ports in the cylinder head. However, the current part only covers 2 ports and you need 2 of these gaskets per cylinder head.

Exhaust Manifold -> Catalytic Converter Fasteners

Part Number
From
To
Comments
Suggested Retail
388718-S2 1992
1994
Stud 7/16 - 14 - 14 x 2.06 Hex S $10.58
N806765-S2 1992
1994
Nut Scr 7 Washr - M8 x 1.25 x 43 ??73?? $8.66





N807988-S100 1995
2002
Stud M12 x 1.75 x 53.0 Shoulder $12.90
N806228-S100 1995
2002
Nut M12 x 1.75 Hex Flange Free $7.02





W709717-S900 2003

Stud M10 x 38 + M10x26 Hx Pil SS $38.98
W705443-S900 2003

Nut M10 x 1.5 Hex Flng Stnls $17.34

Notes: In this area of the country, the studs and nuts which retain the catalytic converter flanges to the exhaust manifolds are usually seized together from corrosion by the time they have to be seperated for a procedure such as transmission overhaul. Some mechanics report success seperating the fasteners with an acetylene torch and pneumatic air wrench, but sometimes the stud snaps or the threads stripout necessating replacement. Drilling out a broken stud is possible, but it an unenjoyable labor intensive task which will require numerous cobalt drill bits along with a low profile air drill. If your vehicle has lived in the dry arid enviroment like the new mexico desert where it seldom percipitates, you can likely disregard these notes and simply spray some penetrant lubricant on the studs and spin the nut off with a regular hand ratchet.

Exhaust Manifold->Engine Block Fasteners

Part Number
From
To
Comments
Suggested Retail
Legacy Part Numbers
N811313-S431 1992
2006
Stud M8x19 + M8x21.7 Hex Point $15.50
W701681-S
W707747-S431 2007
2010
Stud M8 x 19 + M8 x 21.7 Hex Point (4 Per Package)

W701706-S2 1992
2010
Nut M8 Hex Flng P/T MTL $9.46
W701575-S

The cylinder heads are constructed of aluminum. And use of a torch to remove these studs can damage the cylinder head.

5246 H-Pipe Inlet Pipe
connects the catalytic converters to mufflers. Same on both civilian and police models.

F2AZ-5246-D
92-93 Inlet Pipe
"Not Replaced"
F2AZ-5246-B
F4AZ-5246-B
94-94 Inlet Pipe except California Emissions
"Not Replaced"

F4AZ-5246-A
94-94 Inlet Pipe with California Emissions
"Not Replaced"

F5AZ-5246-A
95-97 Inlet Pipe
"Not Replaced"

1W7Z-5246-BA 98-02 Inlet Pipe
$149.99
F8AZ-5246-BA
4W7Z-5246-BA
03-10 Inlet Pipe
$176.36
3W7Z-5246-BA
3W7Z-5246-DA

5230 Muffler assemblies
includes piping that extends to under the rear bumper. Note that during the early 92-94 model years, police cruisers had exhaust resonators like their civilian counterparts.. But 1995 and later police cruisers do not have exhaust resonators, but their civilian counterparts still do.

F4AZ-5230-B
92-94 LH Muffler & Tailpipe Assembly
Obsolete
F2AZ-5230-D
F2AZ-5230-G
F4AZ-5230-D
F4AZ-5230-A
92-94 RH Muffler & Tailpipe Assembly
Obsolete
F2AZ-5230-A
F2AZ-5230-C
F2AZ-5230-E
F2AZ-5230-F
F3AZ-5230-A
F3AZ-5230-B
F5AZ-5230-E
95-97 Police LH Muffler & Tailpipe Assembly
Obsolete

F5AZ-5230-B
95-97 Police RH Muffler & Tailpipe Assembly
Obsolete
F5AZ-5230-A
F8AZ-5230-BA
98-02 Police LH Muffler & Tailpipe Assembly
Obsolete

F8AZ-5230-DA
98-02 Police RH Muffler & Tailpipe Assembly
Obsolete
F8AZ-5230-CA
6W7Z-5230-BC
03-10 Police LH Muffler & Tailpipe Assembly
without fire supression safety pack
$230.03 3W7Z-5230-CA
3W7Z-5230-CD
4W7Z-5230-BB
6W7Z-5230-BB
03-10 Police RH Muffler & Tailpipe Assembly
without fire supression safety pack
$296.30 3W7Z-5230-BA
3W7Z-5230-BB
3W7Z-5230-CC
3W7Z-5230-DB
5W7Z-5230-BB
6W7Z-5230-A 05-10 Police LH Muffler & Tailpipe Assembly
with fire supression safety pack
$317.57 5W7Z-5230-FB
6W7Z-5230-AB
7W7Z-5230-AA
05-10 Police RH Muffler & Tailpipe Assembly
with fire supression safety pack
$457.27 5W7Z-5230-FA
5W7Z-5230-FC
6W7Z-5230-AA

Beginning in the 2005 model year, police interceptors could be ordered with a fire supression system that activates during high energy rear impact collisions.Crownvics with fire supression use a different frame and have different exhaust tailpipes in the back than cars without this system. If you're upgrading a civilian vehicle to dual exhaust, you want to use the police interceptor parts for cars without fire supression.

5E241 Catalytic Converter-> H-Pipe Gasket.

E9AZ-5E241-A
1992-2010 Catalytic Converter->H-Pipe Gasket
$7.98

Note: There are references in service parts literature to a quick disconnect exhaust pipe junction being present near the rear axle on 1998+ crownvics, but this does not appear to have been actually implemented on production vehicles.

5A231 Muffler -> H-Pipe Junction U-Bolt Clamp.
Need two of each clamp. One for left side. One for right side.

D9AZ-5A231-A
92-94 U-Bolt Clamp
51.0
$3.48
F23Z-5A231-A
95-03 2" U-Bolt Exhaust Clamp
51.0*10x1.5
$3.43
W710145-S306
M10 x 1.5 x 55, U-Bolt Bracket Clamp


5260 & 5A205 LH Muffler Hanger

F0VY-5260-A
92-94 LH Muffler Support
"Not Replaced"

F5AZ-5260-A
95-97 LH Muffler Support
"Not Replaced"

F8AZ-5260-AB
98-02 LH Muffler Support
$206.86 F8AZ-5260-AA
3W1Z-5A205-AA
03-10 LH Muffler Support Metal Bracket
$11.64

3W1Z-5A262-AA
03-10 Muffler Support Rubber Insulator
$19.66


The muffler support assembly on the 2003+ cars is orderdd as two seperate service parts. One part is the metal bracket, the other the rubber insulator.

5C263 & 5A204 RH Muffler Hanger

F0VY-5C263-B
92-94 RH Muffler Support
"Not Replaced"
F5AZ-5C263-A
95-97 RH Muffler Support
$103.41
F8AZ-5C263-AA
98-02 RH Muffler Support
$103.41
3W1Z-5A204-AA
03-10 RH Muffler Support Metal Bracket
$9.98
3W1Z-5A262-AA
03-10 Muffler Support Rubber Insulator
$19.66

The muffler support assembly on the 2003+ cars is orderdd as two seperate service parts. One part is the metal bracket, the other the rubber insulator.

5A242 & 5A246 Tailpipe Supports

F6VZ-5A242-AA
92-02 Fits Both LH & RH Sides
$12.03 F0AZ-5A246-A
4W1Z-5A246-AB
03-10 Fits Both LH & RH Sides
$29.98
3W1Z-5A246-AA

If you are upgrading a 03+ civilian crownvic to dual exhaust, you will also want a W712215-S439 Tailpipe Bracket->Frame Bolt.

5F240 Damper on H-Pipe.
These parts are for civilian cars, but they can be installed on police interceptors to lower objectionable exhaust harmonics.

XW7Z-5F240-AB
92-02 LH Damper
Obsolete
F2VY-5F240-C
F2VY-5F240-D
F5AZ-5F240-B
4W1Z-5F240-AA
03- LH Damper
Less Police
$47.10

6W7Z-5F240-AB 03- LH Damper
Less Police
$53.00 3W7Z-5F240-AA
6W1Z-5F240-AA
92-10 RH Damper
Less Police
$35.80
E6AZ-5F240-A
F2VY-5F240-A
F5AZ-5F240-A
XW7Z-5F240-AA

Catalytic Converters

There are hundreds of different catalytic converter assemblies avaliable for the crown vic from your local ford dealership. Each goes with a specific powertrain control module (PCM) calibration in a specific model year. This is why the dealership parts personnel will always ask for your pcm "catchcode" or vehicle identication number (VIN) when you ask them for a cat converter.

However, in terms of physical appearance of the exterior casing and piping of the converter assemblies, the units can be divided into four distinct year ranges: 1992-1994, 1995-1995, 1996-2002, and 2003-2010. And the 1995-1995 units will bolt into a 1996-2002 vehicle or vice versa, but the 1995 catalyst has the old flat bed style cat converters installed on it and the oxygen sensor was located closer to the converter->h-pipe flange so apearance would vary some. However one could assert that there are only three different styles of cat converters avaliable for 1992+ crown vics in terms of fitment issues. And to further consilidate the different catalytic converters, all units from the lincoln town car, mercury grand marquis, and ford crown victoria all share the same exterior appearence and dimensions in a given model year.

In TSB 98-20-10 ford motor company provides information about tightening down loose catalytic converter heat shields using a large FOTZ-5A231-A worm drive clamp. These clamps are not installed from the factory. But if you own an older crownvic with a buzzing cat converter heat shield, you might be able to save yourself the cost of replacing a cat converter by installing one of these clamps.

Aftermarket Exhaust Parts

Maremont (Arvin-Meritor)

Below are a few diagrams for aftermarket Arvin-Meritor exhaust components that are marketed under the maremont brandname.













 








Walker (
Tenneco Automotive)

Below are a couple diagrams of aftermarket crown vic exhaust parts manufactured by tenneco automotive that are marketed under the walker brandname.











 




Here is a link to undercarriage pictures of a 1998 police interceptor that has been through several new england winters.Take note that although the exhaust pipes are constructed of "stainless steel", they have lost a significant portion of their wall thickness due to corrosion. This car also had the steel u-shaped muffler pipe clamps corrode enough that they fell off before these pictures were taken. Chloride salts used in northen states to keep roads clear of snow & ice during the winter months greatly reduce the life of metal parts.

Here is a link to some undercarriage pictures of a 2008 police interceptor that has only been through one new england winter.

Here is some info on installing new muffler hanger rubber insulators on a 1998 crown victoria police cruiser. If you own an older crownvic, this is a repair job that you will want to look at. Rubber "dries out" when it gets old, and a 10 year old crownvic is likely to have muffler hanger insulators ready to fail even if the car has really low mileage on the odometer.


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