Tail Pipe

This procedure covers the removal and replacement of the tail pipe on a 1972 Ford F-100 with 302ci V8 engine, including disconnection from the muffler and removal of mounting hangers.

Warnings

Tools required

Parts

• Tail pipe assembly × 1 — Use OEM specification or aftermarket equivalent
• Tail pipe hanger rubbers × 2 — Standard 1/2 inch exhaust hanger bushings
• Muffler clamp × 1 — 2.25 inch band clamp
• Anti-seize compound × 1 — High-temperature exhaust anti-seize

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks at front wheels
3. Ensure exhaust system is completely cool to the touch
4. Raise rear of vehicle using floor jack at rear axle housing
5. Support vehicle securely on jack stands placed under frame rails behind cab
6. Spray all exhaust clamps and hanger bolts with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Inspect tail pipe routing and hangers
   Position yourself under the rear of the truck and identify the tail pipe connection point at the muffler outlet. Note the location of the tail pipe hangers - typically 2 rubber hanger bushings supporting the tail pipe. On the 1972 F-100, the tail pipe exits behind the rear axle and is supported by hangers attached to the frame; verify the exit side by inspecting the original routing on this truck.
2. 2

   Remove rear tail pipe hanger
   Locate the rearmost tail pipe hanger bushing near the tail pipe exit. Using your hands or a pry tool, pull the tail pipe downward out of the rubber hanger bushing. The pipe has a bent rod welded to it that hooks into the rubber bushing. You may need to rotate the pipe slightly while pulling down to free it from the hanger.
3. 3

   Remove middle tail pipe hanger
   Locate the middle tail pipe hanger bushing approximately 18-24 inches forward of the rear hanger. Pull the tail pipe downward to unhook it from this rubber hanger bushing using the same technique as the rear hanger. With both hangers disconnected, the tail pipe should now hang free, supported only by its connection to the muffler.
4. 4

   Loosen muffler-to-tail pipe clamp
   Locate the band clamp connecting the tail pipe to the muffler outlet. This is typically a 2-piece U-bolt clamp or band clamp. Using a 1/2 inch or 9/16 inch wrench depending on clamp style, loosen and remove the clamp nuts. If the clamp is severely rusted and won't loosen, use a reciprocating saw or hacksaw to cut through one side of the clamp. Remove the clamp completely. Verified detail (1972 Ford F-100 used SAE fasteners exclusively. A 15mm wrench would not be correct for this vehicle's original exhaust hardware. Typical exhaust clamp sizes would be 1/2 inch or 9/16 inch.): Using a 1/2 inch or 9/16 inch wrench depending on clamp style, loosen and remove the clamp nuts.
5. 5

   Separate tail pipe from muffler
   With the clamp removed, twist and pull the tail pipe rearward to separate it from the muffler outlet pipe. The tail pipe typically slides over the outside of the muffler outlet pipe by 3-4 inches. If the connection is corroded and stuck, apply additional penetrating oil and use a twisting motion while pulling. You may need to use a pry bar to carefully spread the tail pipe connection if it is severely corroded.
6. 6

   Remove tail pipe from vehicle
   Once separated from the muffler, maneuver the tail pipe down and rearward to remove it from under the vehicle. Be aware of the bent routing around the rear axle. The pipe should come out easily once fully disconnected.
7. 7

   Inspect and clean muffler outlet
   Inspect the muffler outlet pipe where the tail pipe connected. Use a wire brush to clean any rust, carbon deposits, or old gasket material from the outside of the outlet pipe. This ensures a good seal with the new tail pipe. Check that the muffler outlet pipe is not crushed or damaged.
8. 8

   Inspect and replace hanger bushings
   Inspect both rubber hanger bushings on the frame for cracks, tears, or deterioration. Replace any damaged bushings. The bushings should be firmly mounted to the frame brackets. If they are loose or missing, the hangers must be replaced before installing the new tail pipe.
9. 9

   Prepare new tail pipe
   Unpack the new tail pipe and verify it matches the original in length and bend configuration. Apply a thin coat of high-temperature anti-seize compound to the inside of the tail pipe inlet where it will slip over the muffler outlet pipe. This will ease installation and future removal.
10. 10

    Install new tail pipe onto muffler
    Position the new tail pipe under the vehicle and align the inlet end with the muffler outlet pipe. Slide the tail pipe forward over the muffler outlet pipe, ensuring at least 3 inches of overlap. Route the tail pipe following the original path around the rear axle on the driver side. Do not install the clamp yet.
11. 11

    Connect tail pipe to hangers
    While supporting the tail pipe, lift the front hanger rod on the tail pipe up into its rubber bushing on the frame. You may need to compress the bushing slightly to hook the rod in place. Move to the rear and repeat the process for the rear hanger. Ensure both hangers are fully seated and supporting the tail pipe.
12. 12

    Adjust tail pipe alignment
    With the tail pipe hanging in the rubber bushings, adjust its position to ensure proper clearance from the frame, axle, and body. The tail pipe should hang level and exit behind the truck with at least 1 inch clearance from all components. Rotate the pipe at the muffler connection as needed to achieve proper alignment and exit angle.
13. 13

    Install muffler clamp
    Once alignment is correct, position the new band clamp over the muffler-to-tail pipe connection, centering it over the joint. Install the clamp nuts finger-tight initially. Verify the tail pipe is still properly aligned and fully seated on the muffler outlet, then tighten the clamp nuts in an alternating pattern until snug. Tighten firmly but do not overtighten as this can crush the pipes.
14. 14

    Final inspection
    Perform a final inspection of the installation. Check that both hanger bushings are properly supporting the tail pipe, the clamp is tight and centered on the joint, and there is adequate clearance between the tail pipe and all chassis components throughout its length. Verify the tail pipe exit is positioned correctly behind the vehicle.

Reassembly

1. No disassembly of other components was required for this procedure

Verification

• Start the engine and check for exhaust leaks at the muffler-to-tail pipe connection by listening for hissing sounds and feeling for escaping exhaust gases
• Visually inspect the clamp and connection point while engine is running - there should be no visible smoke or exhaust escaping
• Check that the tail pipe does not contact or rattle against the frame, axle, or body during engine operation
• With engine at operating temperature, verify no unusual exhaust odors are entering the cab
• Take vehicle for short test drive and verify no rattles or vibrations from the exhaust system
• After test drive, re-inspect the clamp and hangers to ensure nothing has loosened

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