This procedure covers the removal and replacement of the rear exhaust pipe section on a 2011-2014 Ford F-150 with the 3.5L EcoBoost V6 engine, including flange connections and exhaust hangers.

Warnings

Tools required

Parts

• Rear exhaust pipe section × 1 — Use OEM specification or quality aftermarket
• Exhaust flange gasket × 2 — Use OEM specification
• Exhaust hanger isolators × 2 — Replace if damaged or cracked

Preparation

1. Ensure engine and exhaust system are completely cool to the touch
2. Park vehicle on level ground and engage parking brake
3. Place wheel chocks behind front wheels
4. Safely raise rear of vehicle and support on jack stands at frame rails
5. Spray all exhaust flange bolts, hanger bolts, and heat shield bolts with penetrating oil and allow 15-20 minutes to soak
6. Inspect exhaust hangers for damage and prepare replacement isolators if needed

Procedure

1. 1

   Remove heat shields if present
   Locate any heat shields attached to the rear exhaust section. Using a 10mm socket, remove the heat shield mounting bolts. Some F-150 configurations have heat shields near the spare tire area. Set shields and hardware aside for reinstallation.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
2. 2

   Disconnect rear exhaust hangers
   Locate the rubber exhaust hanger isolators supporting the rear exhaust section (typically 2 hangers). Use a pry bar or exhaust hanger tool to lever the isolator off the hanger bracket. Work carefully to avoid tearing the rubber. If isolators are cracked or deteriorated, replace them during reassembly.
3. 3

   Remove forward flange connection
   Locate the flange connection where the rear section joins the mid-pipe (typically ahead of the rear axle). Using a 15mm socket with extension, remove the flange bolts. There are typically 2-3 bolts securing this connection. Support the rear section with one hand while removing the final bolt to prevent it from dropping.
   ⚠Bolts may be severely corroded. If bolt heads begin to round, stop and apply more penetrating oil or use a six-point socket.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
4. 4

   Support and remove rear exhaust section
   With the forward flange disconnected and hangers released, carefully maneuver the rear exhaust section rearward and downward to clear the vehicle. The section may be heavy and awkward. Lower it to the ground and move it clear of the work area.
5. 5

   Inspect and clean mounting surfaces
   Remove the old flange gasket from the mid-pipe connection. Use a wire brush to clean the flange mounting surface thoroughly, removing all rust, carbon deposits, and old gasket material. Inspect the flange for cracks or damage. Check that hanger brackets on the frame are intact and not bent.
6. 6

   Prepare new rear exhaust section
   Unpack the new rear exhaust section and verify it matches the original configuration. Install new flange gasket onto the forward connection point of the new pipe. Apply a thin coat of anti-seize compound to the threads of all flange bolts.
7. 7

   Position new rear section
   Lift the new rear exhaust section into position, aligning the forward flange with the mid-pipe connection. Thread in flange bolts by hand to hold the section in place, but do not tighten yet. The section should hang freely at this point.
8. 8

   Connect exhaust hangers
   Align the exhaust pipe hangers with the rubber isolators and frame brackets. Use a pry bar or hanger tool to stretch the isolator over the pipe hanger tab. Ensure each hanger is fully seated and the pipe is properly supported. Adjust pipe position as needed for even clearance around heat-sensitive components.
9. 9

   Torque flange connection
   With the exhaust section properly positioned and supported by hangers, torque the forward flange bolts to specification using a torque wrench. Tighten in a cross pattern if there are 3 or more bolts to ensure even clamping pressure on the gasket.
   ℹ️Proper torque is critical to prevent exhaust leaks. Use a calibrated torque wrench and apply anti-seize as specified.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
10. 10

    Reinstall heat shields
    If heat shields were removed, position them back in their original locations. Install and torque the heat shield bolts to specification. Ensure shields are not contacting the exhaust pipe or creating any interference.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)
11. 11

    Final clearance inspection
    Visually inspect the entire rear exhaust section to verify proper clearance from frame rails, fuel tank, spare tire, and rear suspension components. There should be at least 1 inch of clearance in all directions. Gently rock the exhaust pipe to confirm hangers are properly seated and no contact points exist.

Reassembly

1. Verify all flange bolts are torqued to specification with anti-seize applied
2. Confirm all exhaust hangers are properly seated in isolators
3. Ensure heat shields are reinstalled if originally equipped
4. Check that exhaust tip exits properly behind rear bumper with even spacing

Verification

• Lower vehicle from jack stands and remove wheel chocks
• Start engine and listen for exhaust leaks at the flange connection - there should be no hissing or popping sounds
• Allow engine to reach operating temperature and recheck for leaks
• Perform a brief test drive and listen for any rattles, vibrations, or contact sounds from the exhaust system
• After test drive, re-inspect exhaust hangers and flange connection for any movement or loosening
• Visually confirm no exhaust leaks are present by checking for soot buildup at flange connections

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