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

Warnings

Tools required

Parts

• Tail pipe assembly × 1 — Use OEM specification or equivalent
• Exhaust flange gasket × 1 — Use OEM specification
• Exhaust hanger isolators (if damaged) × 2 — Replace as needed

Preparation

1. Ensure exhaust system is completely cool to the touch
2. Park vehicle on level surface and engage parking brake
3. Apply penetrating oil to all exhaust flange bolts and hanger bolts, allow to soak for 15-20 minutes
4. Raise rear of vehicle using floor jack and support securely on jack stands at frame rails behind rear axle
5. Verify vehicle is stable before working underneath

Procedure

1. 1

   Locate tail pipe connection points
   From underneath the vehicle, locate the tail pipe running from the muffler outlet toward the rear bumper. Identify the flange connection at the muffler outlet and the rubber hanger isolators supporting the tail pipe (typically 2 hangers on the tail pipe section).
2. 2

   Support the tail pipe
   Position a floor jack or support stand under the tail pipe near the muffler connection to support its weight during removal. This prevents the pipe from falling or binding during disassembly.
3. 3

   Remove exhaust flange bolts
   Using a 15mm socket, remove the two bolts securing the tail pipe flange to the muffler outlet flange. These are the Exhaust Flange Bolts. If bolts are severely corroded and will not loosen, apply additional penetrating oil and use a breaker bar. Be prepared for bolts to break if heavily corroded.
   ⚠If bolts break during removal, you may need to drill out the remaining stud and re-tap the threads or use a stud extractor.
   Torque spec

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

   Separate flange connection
   Once bolts are removed, pull the tail pipe rearward to separate the flange connection from the muffler. The flange gasket may be stuck; use a pry bar if necessary to gently separate the flanges. Remove and discard the old gasket.
5. 5

   Remove tail pipe from hangers
   Working from front to rear, release the tail pipe from each rubber hanger isolator. Push or pull the pipe to compress the rubber isolator and slip the hanger hook out. A pry bar or dedicated exhaust hanger tool makes this easier. Inspect rubber isolators for cracking or deterioration and replace if damaged.
6. 6

   Remove tail pipe from vehicle
   Once disconnected from all hangers, carefully lower and remove the tail pipe from under the vehicle. Maneuver the pipe past the rear axle and frame components as needed.
7. 7

   Clean muffler flange surface
   Use a wire brush to thoroughly clean the muffler outlet flange surface, removing all old gasket material, rust, and debris. The flange surface must be clean and flat for proper sealing of the new gasket.
8. 8

   Install new tail pipe on hangers
   Position the new tail pipe under the vehicle and align with the hanger locations. Install the pipe onto the rubber hanger isolators starting from the rear and working forward. Ensure each hanger is fully seated on its hook.
9. 9

   Install new flange gasket
   Position the new exhaust flange gasket onto the muffler outlet flange, aligning the bolt holes. Some gaskets have a raised bead that should face toward the muffler.
10. 10

    Connect tail pipe to muffler
    Align the tail pipe flange with the muffler outlet flange and gasket. You may need to adjust the tail pipe position on the hangers or support it with a jack to achieve proper alignment. Insert both flange bolts finger-tight to hold the connection.
11. 11

    Apply anti-seize and torque flange bolts
    Apply a thin coat of anti-seize compound to the threads of the exhaust flange bolts. Using a torque wrench, tighten the bolts in an alternating pattern to 45.0 Nm (33 lb-ft) as specified for Exhaust Flange Bolts.
    Torque spec

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

    Adjust tail pipe position
    Check the tail pipe alignment and positioning. The pipe should exit near the rear bumper corner with adequate clearance from the bumper, frame, and body components. Adjust position by rotating slightly on the hanger isolators if needed. Ensure equal clearance on all sides to prevent rattling or contact.

Reassembly

1. Verify all exhaust flange bolts are torqued to specification
2. Confirm tail pipe has adequate clearance from all surrounding components
3. Check that all rubber hanger isolators are properly seated and supporting the tail pipe
4. Remove jack stands and carefully lower vehicle to ground

Verification

• Start engine and listen for exhaust leaks at the flange connection; repair if hissing or ticking sounds are present
• Rev engine to 2000-3000 RPM and verify no abnormal exhaust sounds
• Visually inspect the tail pipe from the rear of the vehicle to confirm proper exit position and alignment
• With engine running, check for excessive movement or vibration of the tail pipe
• After a short test drive, re-inspect flange connection and hanger positions to ensure nothing has shifted

More procedures for this vehicle