This procedure covers removal and replacement of the tailpipe assembly on a 2011-2014 Ford F-150 3.5L EcoBoost 4WD, including disconnecting from the muffler and removing exhaust hangers.

Warnings

Tools required

Parts

• Tailpipe assembly × 1 — Use OEM specification or equivalent
• Exhaust flange gasket × 1 — Use OEM specification
• Exhaust flange bolts × 2 — M10 exhaust flange bolts
• Rubber exhaust hangers × 2 — Replace if damaged

Preparation

1. Ensure exhaust system is completely cool to the touch
2. Park vehicle on level ground and engage parking brake
3. Raise rear of vehicle and support securely on jack stands at frame rails
4. Spray exhaust flange bolts and hanger points with penetrating oil and allow to soak for 15-30 minutes
5. Inspect tailpipe routing and note hanger locations for reinstallation

Procedure

1. 1

   Access tailpipe connection
   Position yourself under the rear of the vehicle with adequate lighting. Locate the tailpipe-to-muffler flange connection approximately 12-18 inches forward of the tailpipe exit. Identify the two flange bolts securing the connection.
2. 2

   Support tailpipe
   Have an assistant support the tailpipe or use a jack stand with a block of wood to prevent the tailpipe from falling once disconnected. Position support near the center of the tailpipe assembly.
3. 3

   Remove flange bolts
   Using a 15mm socket, remove the two exhaust flange bolts connecting the tailpipe to the muffler outlet. If bolts are severely corroded, apply additional penetrating oil and allow to soak. Work bolts back and forth if necessary to break corrosion. Discard old bolts and gasket.
   ⚠If bolt heads begin to round, stop immediately and use a six-point socket or bolt extractor to prevent complete rounding.
4. 4

   Disconnect rear exhaust hanger
   Locate the rearmost rubber exhaust hanger supporting the tailpipe, typically 6-10 inches from the tailpipe exit. Using a pry bar or large screwdriver, carefully pry the hanger loop off the rubber isolator mount. Work the metal loop out of the rubber mount by compressing and twisting.
5. 5

   Disconnect middle exhaust hanger
   Locate the middle rubber exhaust hanger supporting the tailpipe forward section. Pry the hanger loop off the rubber isolator mount using the same technique as the rear hanger. The tailpipe should now be free from all attachment points.
6. 6

   Remove tailpipe assembly
   Carefully lower and slide the tailpipe rearward and downward away from the vehicle. Maneuver around any cross members or heat shields as necessary. Inspect rubber hanger mounts on the vehicle for damage or deterioration and replace if cracked or torn.
7. 7

   Clean muffler flange surface
   Using a wire brush, thoroughly clean the mating surface on the muffler outlet flange. Remove all old gasket material, rust, and debris to ensure a proper seal. Inspect flange for cracks or damage.
8. 8

   Prepare new tailpipe
   Position new exhaust flange gasket onto the muffler outlet flange. Apply anti-seize compound to the threads of the new exhaust flange bolts. Verify that rubber hanger loops on new tailpipe are properly positioned and undamaged.
9. 9

   Install tailpipe assembly
   With assistance or using support, raise the new tailpipe into position. Align the forward flange with the muffler outlet flange and gasket. Insert both flange bolts finger-tight. Do not fully tighten yet to allow for hanger alignment.
10. 10

    Connect exhaust hangers
    Working from rear to front, install the tailpipe hanger loops into the rubber isolator mounts on the vehicle. Use a pry bar if necessary to stretch the rubber mounts over the metal loops. Ensure hangers are fully seated and tailpipe hangs evenly.
11. 11

    Align and verify clearances
    Verify the tailpipe has adequate clearance from the frame, fuel tank, spare tire, and rear bumper. Adjust position as needed by shifting at the flange connection or repositioning hangers. Ensure minimum 1 inch clearance from all components and body panels.
12. 12

    Torque flange bolts
    Using a torque wrench and 15mm socket, tighten the exhaust flange bolts to specification in an alternating pattern. Verify flange is pulled together evenly with no gaps at the gasket.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)

Reassembly

1. Double-check all exhaust hanger connections are fully seated
2. Verify all clearances remain adequate after torquing flange bolts
3. Inspect for any tools or parts left under vehicle

Verification

• Start engine and listen for exhaust leaks at the flange connection
• Check for unusual rattling or contact sounds from exhaust system
• Visually inspect tailpipe exit angle and position matches original configuration
• After initial test drive, re-verify all clearances and check flange bolt torque
• Inspect flange connection for exhaust soot indicating leaks after first 50-100 miles

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