I do know on my '04 the system is the more "modular" type, and the owner of the '05 parts car did say that his was a single piece that had both converters.
On one hand, I don't see how the end result could be that much different, since its the same engine in the same body. At worst, I would expect to maybe have to fab up a new hanger. On the other hand ... this project has literally been both a nightmare, and a huge money pit, and the idea of spending ANOTHER $100 on something that may or may not even fit, let alone fix my problem is daunting.
I swear I have never just wanted to bash a vehicle with a ball bat as much as I do with this one.
I guess, if nothing else, I should be able to recoup my money back just scrapping the converters if it doesn't work.
I hear ya... I was that way with my 94 Grand Marquis.. but I loved that car, and it was worth it in the end. Just remember, it is not the vehicle's fault.. some idiot owner or engineer caused this..
The downpipes will not match up with the exhaust manifolds. The 02-04 uses a V-clamp system. On the 05+, both the downpipe and the exhaust manifold have flanges that get bolted together. If you want to attach an 05+ downpipe to an 02-04 exhaust manifold, there is no way to connect them
On the '05 the upstream O-2 sensors are mounted lower than they are on the 02-04. I don't know if that different placement would interfere with any other parts on the 02-04. I'm not familiar enough with the 02-04 to be able to say with certainty.
^ This.. and it's evident in the images that were posted. You can visibly see the height differences in the O2 bungs- not that I think that will cause an issue, but look at how and where they connect to the manifolds. Not compatible.
So at minimum, you would have to swap exhaust manifolds over. If that's doable for you, go for it.. might need to fab a hanger or two underbody.
Personally, I love exhaust v-clamps.. bolt on flanges break, studs and bolts rust, seize, and are a pain to cut off in tight places, exhaust flange gaskets blow out too often.. flanges corrode their welds and fall off.. ugh. no.
V clamps, when they get old and crusty and fail, often don't do or have damage to the flared ends of the pipe. Just replace the clamp and go. Easier to fit in tight spaces, faster installation, no worries about whether it's torqued enough and will leak or not. Kind of go/no-go.