Where is the catalytic converter on a Ford Expedition?

The catalytic converter is located under the vehicle, with one converter for each exhaust bank, typically positioned along the exhaust pipes just downstream of the exhaust manifolds and ahead of the mid-pipe.

In most Ford Expeditions equipped with popular powertrains—such as the 5.4L V8 and the newer 3.5L EcoBoost—the exhaust system includes two catalytic converters, one for each bank. These components are mounted along the undercarriage, usually toward the front half of the truck, and are connected to the exhaust manifolds on both sides. Exact placement can vary slightly by year, engine, and axle configuration, but the general arrangement remains two separate catalysts in the front half of the exhaust routing.

Where to look by engine and year

Common configurations

The exact placement can vary by engine and model year, but the general location remains under the vehicle along the frame, with each bank feeding a separate converter.

• 5.4L/6.8L V8 Expeditions (roughly 1997–2014): two catalytic converters mounted on each exhaust pipe, tucked beneath the vehicle behind the engine, one for each bank, typically just forward of the mid-pipe.


• 3.5L EcoBoost Expeditions (2015–present): two catalytic converters located along the dual exhaust lines, one on each side of the engine, close to the engine bay area but still under the vehicle, ahead of the resonator/mid-pipe.


• General note: Some configurations may use a single combined catalytic converter assembly for certain markets or transmissions; always verify using VIN or service manual for your exact vehicle.

Practically, if you lie on the ground under the front half of the Expedition and follow the exhaust system from the engine toward the middle of the vehicle, you should spot two metal canisters with heat shielding attached to the exhaust pipes—these are the catalytic converters. They connect to the exhaust manifolds and to the rest of the exhaust via flanges or clamps.

How to identify and service safely

Preparation and safety

Before inspecting or working on the catalytic converters, ensure the vehicle is cool, securely supported, and that you have the proper tools and instructions. Work in a well-ventilated area and use appropriate safety gear.

• Use jack stands or a lift to safely access the underside; never rely on a jack alone.


• Look for the two catalytic converter canisters along the exhaust path, typically protected by heat shielding and mounted to the frame or exhaust hangers.


• Inspect for rust, leaks, loose or damaged flanges, and malfunctioning oxygen sensor wiring nearby, which can indicate converter or exhaust system issues.

If you’re not completely confident identifying or replacing catalytic converters, consult a qualified mechanic or Ford-certified technician for your specific VIN/year, since exact layouts can vary across trims and production runs.

Summary

On a Ford Expedition, catalytic converters are usually arranged as two separate units, one for each exhaust bank, located under the vehicle along the exhaust routing just downstream of the exhaust manifolds and ahead of the mid-pipe. The precise location can vary by engine type (such as the 5.4L V8 or the 3.5L EcoBoost) and model year, but the two-converter configuration is common across most modern Expeditions. Use the vehicle’s manual or VIN-specific service information to confirm exact placement and replacement procedures.

Where is the catalytic converter located?

A catalytic converter is located in the exhaust system, typically underneath the vehicle, between the engine and the muffler. It may be close to the engine, near the middle of the car, or sometimes integrated into the exhaust manifold. Many vehicles have more than one converter. 
This video shows the location of a catalytic converter on a Ford F-150: 59s2CarProsYouTube · Apr 26, 2025
Typical locations

• Under the vehicle: It is a common practice to place the converter along the exhaust pipe underneath the passenger compartment. 
• Near the engine: Some converters are placed closer to the engine to heat up faster, and in many modern vehicles, a converter is integrated into or placed directly after the exhaust manifold. 
• Middle of the car: A main catalytic converter is often found under the middle of the vehicle, roughly around the passenger's feet. 
• Multiple converters: Vehicles, especially those with V6 or V8 engines, often have multiple catalytic converters. This can include two smaller converters near the engine (one for each bank of cylinders) and a larger one further down the exhaust system. 

You can watch this video to learn more about the catalytic converter and its location in the exhaust system: 56sAutoCatalyst Market: Catalytic Converter PricesYouTube · Oct 5, 2022

How many catalytic converters are on a 2003 Ford Expedition?

The 2003 Ford Expedition typically has two catalytic converters—one for each exhaust bank in the V8 engine. Symptoms of failing converters include poor acceleration, check engine light, and failed emissions tests. To troubleshoot, inspect for rattling noises or sulfur smells.

How much does it cost to replace a catalytic converter on a Ford Expedition?

Replacing a catalytic converter on a Ford Expedition typically costs between $1,600 and $2,500, including parts and labor, but can range from $200 to over $2,000 depending on factors like the specific model year, location, and the type of converter used (direct-fit vs. universal). You can save money with a less expensive universal part and by doing the work yourself, but this requires knowing how to properly install it and address any underlying issues that caused the original converter to fail. 
Factors that influence the cost

• Type of converter: A direct-fit or OEM converter is more expensive, while a universal converter is cheaper but may require welding to install. 
• Emissions standards: Parts that meet California's strict emissions standards (CARB) will cost more than federal (EPA) compliant parts. 
• Labor costs: Labor can range from $70$ 70$70 to $130$ 130$130 per hour, plus any additional shop materials and taxes. 
• Vehicle's condition: Any underlying problems that caused the original converter to fail (like a blown head gasket or cracked exhaust manifold) must be fixed to prevent damage to the new part. 
• Number of converters: Vehicles with V8 engines often have two catalytic converters, and it's best practice to replace them at the same time. 

Ways to save money

• Shop around: Prices can vary between different shops and dealerships. Get multiple quotes. 
• Consider a universal converter: This is the cheapest option if your state does not require a direct-fit converter. 
• Replace it yourself: If you are mechanically inclined, you can save on labor costs by replacing the part yourself. 

Does a Ford Expedition have a catalytic converter?

The catalytic converter is a part of your Ford Expedition Max's exhaust system.