This procedure covers the replacement of an exhaust clamp on a 2015-2020 Ford F-150 with the 3.5L EcoBoost V6 engine, including inspection of surrounding exhaust components.

Warnings

Tools required

Parts

• Exhaust clamp × 1 — Use OEM specification or equivalent band clamp
• Anti-seize compound × 1 — Nickel or copper-based

Preparation

1. Ensure engine and exhaust system are completely cool to the touch
2. Park vehicle on level ground and apply parking brake
3. Place wheel chocks behind rear wheels
4. Raise vehicle using floor jack at manufacturer-specified lift points
5. Support vehicle securely on jack stands rated for vehicle weight
6. Spray penetrating oil on clamp fasteners and allow 10-15 minutes to penetrate

Procedure

1. 1

   Locate and inspect exhaust clamp
   Position yourself under the vehicle and locate the failed or damaged exhaust clamp. On the 3.5L EcoBoost, common clamp locations include connections between the downpipes and mid-pipe, or mid-pipe to muffler sections. Visually inspect the clamp for cracks, stripped threads, or corrosion damage. Note the clamp orientation and position for reinstallation.
2. 2

   Support exhaust section
   If the clamp is holding a joint that will separate when removed, support the downstream exhaust section with a jack stand or have an assistant support it to prevent stress on exhaust hangers. Check that exhaust hangers are intact and properly positioned.
3. 3

   Remove old exhaust clamp
   Loosen and remove the clamp fastener(s). For band-style clamps, loosen the bolt until the clamp can be opened and removed. For U-bolt style clamps, remove both nuts. If fasteners are seized, apply additional penetrating oil and use a six-point socket to prevent rounding. Carefully remove the old clamp and set aside.
4. 4

   Clean exhaust pipe surfaces
   Using a wire brush, thoroughly clean both exhaust pipe ends where the clamp will mate. Remove all carbon deposits, rust, and old gasket material. Ensure the pipe surfaces are smooth and free of debris to create a proper seal. Inspect pipe ends for cracks, excessive corrosion, or damage that would prevent a proper seal.
5. 5

   Check alignment and fit
   Align the exhaust pipes to ensure they mate properly. The slip joint should slide together smoothly with the inner pipe inserted approximately 1.5-2 inches into the outer pipe. Adjust exhaust hangers if necessary to achieve proper alignment. Verify there is adequate clearance from frame, fuel lines, brake lines, and driveshaft.
6. 6

   Install new exhaust clamp
   Position the new clamp over the exhaust joint, ensuring it is centered on the connection. For band clamps, orient the fastener in an accessible location where it can be tightened without interference. For U-bolt clamps, ensure the saddle is properly seated. Hand-thread fasteners initially to verify proper fit and alignment.
7. 7

   Tighten exhaust clamp
   Tighten the clamp fasteners in a progressive manner. For band clamps, tighten the bolt evenly while ensuring the band does not twist. For U-bolt clamps, alternate between nuts to ensure even pressure. Follow manufacturer torque specifications for the specific clamp type. If using a generic clamp, tighten to 40-45 ft-lbs or per clamp manufacturer specifications. Do not overtighten as this can crush or crack the exhaust pipe.
8. 8

   Verify exhaust hanger positions
   Check that all exhaust hangers in the affected area are properly seated in their mounting points and not damaged. The exhaust system should hang with adequate clearance from the chassis and suspension components. Adjust hangers as needed to achieve proper positioning.
   Torque spec

   Hanger Bolts23 Nm (17 lb-ft)
9. 9

   Inspect heat shields
   Verify that any heat shields near the clamp location are properly secured and not damaged. Tighten or replace any loose or damaged heat shield bolts to prevent rattles and maintain proper heat protection.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Double-check all clamp fasteners are properly tightened
2. Ensure exhaust system has proper clearance from chassis, fuel lines, brake lines, and driveshaft
3. Verify all exhaust hangers are properly positioned and supporting the system

Verification

• Lower vehicle from jack stands carefully
• Start engine and allow to idle, listening for exhaust leaks at the clamp location (hissing or ticking sounds indicate a leak)
• With engine running, visually inspect the clamp area for any visible exhaust gases escaping
• Rev engine slightly (1500-2000 RPM) and verify no exhaust leaks are present
• After engine reaches operating temperature, recheck for leaks as heat expansion may reveal issues
• Test drive vehicle and listen for rattles or unusual exhaust noises
• After initial test drive, allow to cool slightly and retighten clamp fasteners if necessary

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