Below are some parts diagrams and other notes about crown victoria exhaust systems that you may find useful.:

• The exhaust system on crown vics can be broken into four distinct year ranges within which parts can be interchanged. The 92-94, 95-97, 98-02, and 03-10 revisions.
  
• what people like their exhaust system to sound like varies widely. some like it loud, some like it soft. but for police work, an exhaust that rattles home walls is undesirable particulary when the vehicle is used for covert surveliance work.
• a crown victoria exhaust of the same year will fit on a grand marquis of the same year. but a crown victoria exhaust components will not fit on a towncar or vice versa.
  
• similarly, mustang gt exhaust pipes will not fit on a crown vic due to the obvious size differences between the two cars. you could probably use mustang gt mufflers if you were handy with a welder though.
• most of the inexpensive aftermarket exhaust pipes are made of low carbon steel or aluminized steel which will have an expected lifespan of 2-4 years. older original equipment ford exhaust components for "box body" crown vics are also constructed of this material.
• original equipment ford exhaust parts for 1992 & later crown vics are made of a ferritic series stainless steel such as t-409 which yields increased component life but does not significantly increase the manufacture cost of the vehicle. if you place a magnet on the tailpipe of your crown vic, it'll stick. expected lifespan of 400 series ferritic exhaust components is typically somewhere around 10 years. visible surface rust on the exhaust components after a few months of use is considered normal
  
• borla makes an aftermarket cat-back exhaust system with a nice rumble sound to it for 98-02 crown victorias that's constructed of t-304 stainless steel. lifespan of the pipes can easily exceed 20 years and they'll also maintain their shiny chrome appearance indefinetly. see also www.borla.com
  
• exhaust systems corroded from both sides of the pipe. on the outside, chloride salts used to clear streets in the winter are a big enemy. on the inside, water, acids and combustion engine byproducts eat away. combustion byproducts deposits are a significant problem on cars that are used for short "around town" trips where the car never fully "warms up". plus police vehicles have all sorts of offroading adventures that can bend & scrape the pipes
• note that in some very hot & dry areas such as the california & nevada deserts where it often doesn't rain for months at a time, even t-409 stainless steel can maintain a polished appearance like surgical stainless. but this is rare, and undercarriage t-409 stainless steel components will typically have a little surface rust on them in most enviroments.
  
• police & hpp crown vics all have a factory installed dual exhaust system. others are single. to convert to dual exhaust, one needs to replace the single outlet "y-pipe" after the catalytic converters with a dual outlet "h-pipe",  install new hangers and install a new drivers tailpipe assembly.
  
• wrecked police cruisers are very easy to come by. wrecked hpp crown vics are not. and many yards aren't going to be sure whether they have an hpp crown vic or not if you  call them on the phone.
• there is a federal law against selling used catalytic converters
• there is no federal law about selling used exhaust parts. but some states do have their own laws prohibiting sale of any exhaust components. additionally, many yards don't want to be bothered with the effort of pulling off exhaust parts when they can sell real parts for real money. and most of the yards that specialize in late model cars are not "self service".
• if you're considering using an internet based ford dealership to order your parts, be warned that some exhaust system components such as the 5230 muffler & tailpipe assemblies are very bulky and will require special shipping arrangements. ford part prices are not cheap. but exhaust systems take a huge amount of space to store. and are expensive to ship between facilities too.
  
• hpp crown vics have resonators in tailpipes. 95+ police crown vics do not have resonators in tailpipes. very early 92-94 p71's did have resonators though.
  
• the exhaust pipes will not slide over rear axle without cutting the pipe or removing the axle housing. 98+ crown vic exhaust pipes already have a factory installed junction in the pipe near the rear axle to ease in removal. but 97' & prior vehicles do not.
• 1995+ crown vics have rear oxygen sensors mounted on the catalytic converters for obd2 catalyst efficency monitors
• The aftermarket catalytic converters for 1995 and earlier crown vics have two catalytic converters per car. The aftermarket units for 1996 and later ones have 4 per car.
• crown vic frames do flex a little bit. so make sure to use flexible rubber insulators on mounting brackets to help prevent cracks. 
• crown vic owners have had mixed success with custom fabricated exhaust systems in regards to banging noises and cracks developing. no one appears to have had problems with borla though. 
• http://www.innovativeinterceptors.com sells nice looking marauder turn down exhaust outlets "Innovative Interceptors Exclusive: Marauder Exhaust Tips by Meg's with Resonator Delete."
  

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:

• The early 1992-1994 exhaust manifolds have the oxygen sensors mounted in the manifold rather than in the catalytic converter assemblies like on later models.
• The outlet diameter of the manifold where the catalytic converter flange mounts on the 1992-1994 vehucles is slightly larger than on 1995-2002 vehicles.
• All 1992-2004 crown vics use the same mounting pattern on the cylinder head for the exhaust manifolds. This is very convient if one desires to install a 2010 engine into a 1992 crown vic because the original 1992 manifolds will bolt onto a 2010 engine block

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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