Exhaust Hangers

This procedure covers the inspection and replacement of exhaust system rubber hangers on the 2015-2020 Ford F-150 with 3.5L EcoBoost V6 engine.

Warnings

Tools required

Parts

• Exhaust hanger(s) × 1 — Use OEM specification - typically BC3Z-5A231-A or similar

Preparation

1. Ensure exhaust system is completely cool to the touch
2. Park vehicle on level surface and engage parking brake
3. Lift rear of vehicle with floor jack and support securely on jack stands rated for vehicle weight
4. Inspect all exhaust hangers from underneath to identify worn, cracked, or separated hangers
5. Apply penetrating oil to hanger mounting bolts if replacing frame-mounted hanger brackets

Procedure

1. 1

   Locate the damaged hanger
   Position yourself under the vehicle with adequate lighting. The F-150 3.5L EcoBoost has rubber hangers typically located at: mid-pipe junction (after catalytic converters), rear of mufflers, and tailpipe exit points. Identify the specific hanger requiring replacement by visual inspection for cracks, tears, or separation from mounting points.
2. 2

   Support the exhaust system
   Before removing the hanger, ensure the exhaust pipe will not fall or shift. If replacing a load-bearing hanger, support the exhaust component with a jack stand or block of wood to prevent stress on adjacent hangers and joints. The dual exhaust system is heavy and can damage flanges if allowed to hang freely.
3. 3

   Remove exhaust pipe from hanger
   Using a pry bar or large flathead screwdriver, carefully pry the exhaust pipe rod out of the rubber hanger grommet. Apply leverage from multiple angles if necessary. For severely deteriorated hangers, you may need to cut the old rubber away. Work the pipe free by pushing upward on the exhaust while prying the hanger loop.
4. 4

   Remove old hanger from frame bracket
   Most hangers slip off the frame-mounted bracket by pulling perpendicular to the bracket rod. For bolt-on hanger brackets that require replacement, remove the mounting bolts using appropriate socket. Frame-mounted brackets may be rusted; use penetrating oil and wire brush as needed. Note the orientation of the hanger for correct installation.
5. 5

   Clean mounting surfaces
   Wire brush the frame bracket rod and exhaust pipe hanger rod to remove rust, debris, and old rubber residue. Clean surfaces ensure proper seating of the new rubber hanger and prevent premature failure. Inspect the metal hanger rods on both exhaust and frame for damage or excessive corrosion that would require additional repairs.
6. 6

   Install new hanger onto frame bracket
   Slip the new rubber hanger onto the frame-mounted bracket rod first. Ensure the hanger is oriented correctly with the loop positioned to accept the exhaust pipe rod. The hanger should seat fully against any stops or shoulders on the bracket. For bolt-on brackets, position the new bracket and start bolts hand-tight.
   Torque spec

   Hanger Bolts23 Nm (17 lb-ft)
7. 7

   Connect exhaust pipe to hanger
   Apply slight upward pressure on the exhaust pipe to align with the hanger loop. Using a pry bar for leverage, stretch the rubber hanger to slip over the exhaust pipe rod. Work one side of the loop over first, then the opposite side. The rod should be centered in the hanger grommet. Remove any temporary support from under the exhaust.
8. 8

   Verify exhaust alignment
   Visually inspect the exhaust system to ensure proper clearance from the frame, driveshaft, fuel tank, and spare tire. The pipes should hang evenly with approximately 1-2 inches of clearance to surrounding components. Check that the tailpipes exit parallel to the bumper. Adjust by repositioning at adjacent hangers if necessary.

Reassembly

1. If hanger bracket bolts were removed, torque to specification using calibrated torque wrench
2. Verify all exhaust hangers are properly engaged on both frame and pipe mounting points
3. Confirm exhaust system has adequate clearance and is not contacting frame or suspension components

Verification

• Lower vehicle from jack stands and remove all tools from under vehicle
• Start engine and verify no exhaust leaks or unusual vibrations from the repaired area
• With engine running, have assistant observe exhaust system while you apply throttle in park to check for excessive movement or contact
• Test drive vehicle and listen for any rattling, buzzing, or contact noises from exhaust system
• After test drive, re-inspect hanger installation to ensure it remained properly seated

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