This procedure covers removal and replacement of the intermediate exhaust pipe on a 2011-2014 Ford F-150 with 5.0L V8 Coyote engine, including disconnecting exhaust flanges and hangers.

Warnings

Tools required

Parts

• Intermediate exhaust pipe assembly × 1 — Use OEM specification
• Exhaust flange gaskets × 2 — Use OEM specification
• Exhaust hanger isolators (if damaged) × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow exhaust system to cool completely (minimum 2 hours after engine operation)
3. Raise vehicle using floor jack and support securely on jack stands at frame rails
4. Spray all exhaust flange bolts and hanger bolts with penetrating oil and allow to soak for 30 minutes
5. Visually inspect intermediate pipe routing and note positions of exhaust hangers and heat shields

Procedure

1. 1

   Remove oxygen sensors
   Using a 22mm oxygen sensor socket, carefully remove the downstream oxygen sensors from the intermediate pipe. Turn counterclockwise and apply steady pressure. If sensors are being reused, protect the sensor tips from damage and contamination. Set sensors aside in a clean area.
   ⚠Do not use impact tools on oxygen sensors. Hand tools only to prevent internal damage to the sensor.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
2. 2

   Remove heat shields
   Remove any heat shields attached to the intermediate pipe using a 13mm socket. There may be multiple heat shields depending on configuration. Keep hardware organized for reinstallation.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
3. 3

   Disconnect front exhaust flange
   Locate the front flange connection between the catalytic converters and intermediate pipe. Remove the two or three flange bolts using a 15mm socket while supporting the intermediate pipe weight. The pipe may be stuck to the gasket; gently wiggle to break the seal. Do not pry against catalytic converter bodies.
   ⚠Support the intermediate pipe weight before removing final flange bolt to prevent pipe from dropping suddenly.
   Torque spec

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

   Disconnect rear exhaust flange
   Move to the rear flange connection between the intermediate pipe and rear muffler assembly. Remove the flange bolts using a 15mm socket. On 4WD models, you may need to maneuver around the transfer case and front driveshaft for access. Support the rear of the intermediate pipe.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
5. 5

   Remove exhaust hanger bolts
   Locate the rubber exhaust hangers supporting the intermediate pipe (typically two hangers). Remove the hanger mounting bolts using a 13mm socket. Note the orientation and position of hangers for reinstallation.
   Torque spec

   Hanger Bolts25 Nm (19 lb-ft)
6. 6

   Remove intermediate pipe
   With all connections disconnected, carefully lower and remove the intermediate pipe from the vehicle. On 4WD models, angle the pipe to clear the transfer case and front driveshaft. The pipe may need to be rotated and maneuvered to clear frame members and crossmembers.
   ℹ️Have a helper assist with pipe removal to prevent damage to surrounding components during extraction.
7. 7

   Clean flange surfaces
   Using a wire brush, thoroughly clean all flange mating surfaces on the catalytic converters and rear muffler assembly. Remove all old gasket material, carbon deposits, and corrosion. Ensure surfaces are flat and smooth for proper sealing.
   ⚠Wear safety glasses and work in well-ventilated area when cleaning exhaust components to avoid inhaling carbon particles.
8. 8

   Inspect and prepare new intermediate pipe
   Inspect the new intermediate pipe for shipping damage and verify oxygen sensor bungs are present and undamaged. Apply anti-seize compound to oxygen sensor threads (threads only, not sensor tips). Install new flange gaskets on both ends of the intermediate pipe.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
9. 9

   Install intermediate pipe
   Carefully maneuver the new intermediate pipe into position, routing it around the transfer case and driveshaft on 4WD models. Align the front flange with the catalytic converter outlet and rear flange with the muffler inlet. Insert exhaust hangers into their rubber isolators but do not tighten bolts yet.
   ℹ️Do not fully tighten any connections until all components are aligned and in position to allow for adjustment.
10. 10

    Install front flange connection
    Apply anti-seize compound to the threads of the front exhaust flange bolts. Install bolts finger-tight, ensuring the flange gasket remains properly positioned. Verify alignment before tightening.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
11. 11

    Install rear flange connection
    Install the rear flange bolts finger-tight, ensuring proper gasket placement and flange alignment. Check that the intermediate pipe is properly supported by the exhaust hangers and not binding or stressed.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
12. 12

    Torque exhaust connections
    Starting with the front flange, torque the exhaust flange bolts to 45 Nm (33 lb-ft) in a cross-pattern. Then torque the rear flange bolts to 59 Nm (44 lb-ft) in a cross-pattern. Torque the hanger bolts to 25 Nm (19 lb-ft). This sequence ensures proper alignment and sealing.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)

    Hanger Bolts25 Nm (19 lb-ft)
13. 13

    Install oxygen sensors
    Apply fresh anti-seize compound to oxygen sensor threads only (avoid getting compound on sensor tips). Thread sensors into the intermediate pipe bungs by hand, ensuring threads engage properly. Torque oxygen sensors to 45 Nm (33 lb-ft) using the oxygen sensor socket. Reconnect oxygen sensor electrical connectors and secure wiring away from hot exhaust components.
    ⚠Never apply anti-seize to oxygen sensor tips. Contamination will cause sensor failure and incorrect readings.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)
14. 14

    Reinstall heat shields
    Reinstall all heat shields in their original positions and torque the heat shield bolts to 10 Nm (7 lb-ft). Ensure heat shields do not contact the exhaust pipe or create rattle points.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Double-check all exhaust connections are properly torqued and no tools or parts were left under the vehicle
2. Verify oxygen sensor wiring is routed away from exhaust components and secured with original clips
3. Inspect all exhaust hangers to ensure they are properly seated in rubber isolators

Verification

• Lower vehicle to ground and start engine, allowing it to idle
• Listen for exhaust leaks at both flange connections while engine is running
• Check for any abnormal vibrations or rattles from the exhaust system
• Perform a brief test drive and recheck all connections for leaks or looseness
• Use a scan tool to verify oxygen sensors are reading properly and no diagnostic codes are present
• After first 50 miles of driving, re-torque all exhaust flange connections as exhaust gaskets may settle

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