This procedure covers the removal and installation of the exhaust tip on a 2015-2020 Ford F-150 with the 3.5L EcoBoost V6 engine, including clamp-on and bolt-on configurations.

Warnings

Tools required

Parts

• Exhaust tip (replacement) × 1 — Ford OEM or aftermarket compatible with 3.5L EcoBoost dual exhaust
• Exhaust clamp (if clamp-on style) × 1 — Use OEM specification or aftermarket stainless steel

Preparation

1. Ensure vehicle has been off for at least 2 hours and exhaust system is completely cool to the touch
2. Park vehicle on level ground, engage parking brake, and place wheel chocks behind front wheels
3. Raise rear of vehicle using floor jack at designated rear axle jacking points and support with jack stands rated for vehicle weight
4. Verify vehicle is stable before working underneath
5. Spray all exhaust tip fasteners (clamp or flange bolts) with penetrating oil and allow 15-20 minutes soak time

Procedure

1. 1

   Locate and inspect exhaust tip mounting
   Position yourself under the rear of the vehicle and locate the exhaust tip on the side requiring service. The 3.5L EcoBoost uses a dual exhaust system with tips exiting behind the rear wheels. Identify whether your exhaust tip uses a band clamp (common on factory chrome tips) or a bolted flange connection (common on aftermarket systems). Inspect for rust, corrosion, or damage to mounting hardware.
2. 2

   Remove clamp-on style exhaust tip (if applicable)
   If equipped with a band clamp, locate the clamp bolt (typically 13mm or 15mm) positioned on the underside or rear of the connection point. Using the appropriate socket and ratchet, loosen the clamp bolt counterclockwise. You do not need to fully remove the bolt—loosen it until the clamp is free to expand. Twist the exhaust tip back and forth while pulling rearward to break the seal and slide it off the exhaust pipe. If stuck, apply additional penetrating oil at the joint and allow more soak time.
3. 3

   Remove bolted flange style exhaust tip (if applicable)
   If equipped with a flanged connection, locate the two or three flange bolts securing the tip to the exhaust pipe (typically 13mm). Support the exhaust tip weight with one hand while removing the flange bolts counterclockwise with a socket and ratchet. Remove all bolts and carefully lower the exhaust tip away from the flange connection. Inspect the gasket or seal at the flange—replace if damaged or deteriorated.
4. 4

   Clean mounting surfaces
   Use a wire brush to thoroughly clean the exhaust pipe outlet where the tip mounts. Remove all carbon buildup, rust, and old gasket material from flange surfaces if applicable. For clamp-on styles, clean the outer diameter of the exhaust pipe to ensure a proper seal with the new tip. Wipe clean with a shop rag.
5. 5

   Prepare new exhaust tip for installation
   Inspect the new exhaust tip for any shipping damage or defects. If using a flanged connection, apply a thin coat of anti-seize compound to the flange bolt threads. For clamp-on styles, ensure the internal diameter matches the exhaust pipe outer diameter. Position any required gasket or seal at the flange connection if applicable.
6. 6

   Install new exhaust tip onto tailpipe
   For clamp-on style: Slide the new exhaust tip onto the exhaust pipe, ensuring it seats fully against the internal stop or to the desired depth (typically 2-3 inches of overlap). Rotate the tip to achieve proper alignment with the bumper cutout—the outlet should be centered and level. Position the band clamp over the connection joint and thread the clamp bolt finger-tight. For flanged style: Align the tip flange with the exhaust pipe flange, ensuring the gasket is properly seated. Thread all flange bolts finger-tight before proceeding to torque.
7. 7

   Torque fasteners to specification
   For clamp-on style: Tighten the clamp bolt gradually in a cross pattern if multiple bolts exist, checking tip alignment as you tighten. Clamp bolts typically require 23-30 Nm but do not over-tighten as this can crack the tip. For flanged connections: Using a torque wrench, tighten flange bolts to 45 Nm (33 lb-ft) in a star or crossing pattern to ensure even clamping force and prevent warping the flange.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
8. 8

   Verify exhaust tip alignment and clearance
   Step back and visually inspect the exhaust tip position from behind the vehicle. The tip should be centered in the bumper cutout, level with the ground, and positioned at the proper depth. Check clearance between the tip and bumper fascia—there should be at least 0.5 inches of clearance all around to prevent heat damage or rattling. Adjust position if necessary by loosening the clamp or flange, repositioning, and re-torquing.

Reassembly

1. Lower vehicle from jack stands using floor jack, then remove jack stands and lower completely to ground
2. Remove wheel chocks and verify all tools and parts have been removed from under vehicle
3. If dual exhaust tips were replaced, repeat procedure for opposite side to ensure matching appearance

Verification

• Start the engine and verify no exhaust leaks are present at the tip connection—listen for hissing or unusual exhaust noise
• Allow engine to reach operating temperature and recheck for leaks, as heat expansion may reveal issues not apparent when cold
• Visually inspect exhaust tip alignment from multiple angles to ensure proper positioning and appearance
• After first drive cycle (approximately 50 miles), recheck clamp or flange bolt tightness as heat cycling may cause slight loosening

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