exhaust

Muffler

for 2017 Ford F-150 3.5L V6 EcoBoost · RWD

Difficulty

Moderate

Time

1.2 h

Tools

Steps

This procedure covers the removal and replacement of the muffler on a 2015-2020 Ford F-150 with the 3.5L EcoBoost V6 engine, including all necessary hangers, clamps, and hardware.

Warnings

⚠️Allow exhaust system to cool completely before starting work. Exhaust components can remain hot for several hours after engine operation and cause severe burns.

⚠Exhaust fasteners and clamps may be corroded and require penetrating oil or cutting. Apply penetrating oil 24 hours before starting if possible.

⚠Ensure vehicle is securely supported on jack stands rated for the vehicle weight. Never work under a vehicle supported only by a floor jack.

ℹ️The muffler is located mid-vehicle, approximately below the rear passenger door area on RWD models.

Tools required

Floor jack and jack standsEssential

Torque wrench (10-100 Nm range)Essential

15mm socket and ratchetEssential

14mm socket and ratchetEssential

13mm socket and ratchetEssential

3/8 drive extension setEssential

Penetrating oil

Wire brush

Anti-seize compoundEssential

Exhaust hanger removal tool

Reciprocating saw or pipe cutter (if cutting rusted components)

Parts

Muffler assembly × 1 — Use OEM specification or approved aftermarket equivalent
Exhaust clamp (if not included with muffler) × 2 — Use OEM specification
Exhaust flange gasket × 1 — Use OEM specification
Rubber exhaust hangers × 2 — Replace if worn or cracked

Preparation

Park vehicle on level surface and allow exhaust system to cool completely (minimum 2 hours after operation)
Apply penetrating oil to all exhaust clamps, flange bolts, and hanger brackets if corrosion is visible
Raise vehicle using floor jack at manufacturer-specified lift points
Support vehicle securely on jack stands at frame rails, ensuring minimum 18 inches of working clearance
Visually inspect exhaust system from catalytic converters to tailpipe to identify muffler location and connection points
Spray all visible fasteners with additional penetrating oil and allow 15 minutes soak time

Procedure

1
Support exhaust system
Position a floor jack with a block of wood under the muffler to support its weight during removal. Raise jack until it just contacts the muffler but does not lift the vehicle. This prevents the exhaust from dropping suddenly when disconnected.
2
Disconnect rear exhaust hanger
Locate the rubber exhaust hanger at the rear of the muffler (toward the tailpipe). Using an exhaust hanger removal tool or flat pry bar, carefully pry the hanger grommet off the support bracket. Work the rubber grommet side-to-side while pulling to remove without tearing.
3
Disconnect front exhaust hanger
Locate the rubber exhaust hanger at the front of the muffler (toward the engine). Remove the hanger grommet from its bracket using the same technique as the rear hanger. If hangers are cracked or deteriorated, plan to replace them during reassembly.
4
Remove rear muffler clamp
Locate the band clamp or V-band clamp connecting the muffler outlet to the tailpipe section. Using a 15mm socket, remove the clamp bolts completely. If clamp is severely corroded, apply heat or use a reciprocating saw to cut the clamp. Remove and discard the clamp.
⚠If using heat or cutting tools, ensure no fuel lines or brake lines are nearby. Keep fire extinguisher accessible.
Torque spec
Muffler Clamps55 Nm (41 lb-ft)
5
Separate muffler from tailpipe
With the clamp removed, twist and pull the tailpipe section away from the muffler outlet pipe. The tailpipe should slide off the slip joint. If stuck, apply penetrating oil to the joint and use a twisting motion while pulling. Lower the jack slightly if needed to create clearance.
6
Remove front connection
Identify the front connection type. If flange-style connection: Remove the two or three flange bolts using a 14mm socket. If clamp-style connection: Remove the clamp bolts using a 15mm socket. Keep track of any spacers or alignment rings at the flange connection.
ℹ️EcoBoost models typically use a flange connection at the front of the muffler connecting to the mid-pipe or resonator section.
7
Remove old flange gasket
If flange connection was used, separate the muffler from the front pipe and remove the old exhaust gasket. Discard the old gasket. Use a wire brush to clean both mating surfaces of the flange thoroughly, removing all carbon deposits and old gasket material.
8
Remove muffler assembly
Lower the floor jack slowly while guiding the muffler down and out from under the vehicle. Maneuver the muffler around the driveshaft and any cross members. Remove the muffler from under the vehicle.
9
Inspect and prepare mounting points
Inspect all hanger brackets on the vehicle frame for cracks or damage. Wire brush all mounting surfaces, clamp areas, and flange surfaces clean. Inspect rubber hangers and replace if cracked, torn, or hardened. Check that exhaust hanger brackets are secure to the frame.
10
Install new muffler
Position the floor jack under the new muffler and raise it into approximate position under the vehicle. Align the muffler inlet with the front pipe connection point. If using flange connection, install new exhaust gasket onto the front pipe flange with the metal reinforcement ring facing forward.
11
Connect front flange or clamp
Align the muffler inlet flange with the front pipe flange. Apply anti-seize compound to flange bolt threads. Install flange bolts finger-tight. If clamp-style, position clamp over the slip joint and install bolts finger-tight. Do not torque at this stage.
ℹ️Leave all connections loose until the entire system is aligned to prevent binding and stress on mounting points.
12
Connect tailpipe section
Slide the tailpipe section onto the muffler outlet pipe, ensuring overlap of at least 2 inches at the slip joint. Rotate to align properly with the rear hangers. Position the muffler clamp over the joint and install clamp bolts finger-tight.
Torque spec
Muffler Clamps55 Nm (41 lb-ft)
13
Install exhaust hangers
Connect the front muffler hanger grommet to its frame bracket. Use a pry bar or hanger tool to stretch the rubber grommet over the bracket hook. Repeat for the rear hanger. Ensure hangers are fully seated and not twisted.
14
Align exhaust system
Adjust the position of the muffler assembly to ensure proper clearance from the driveshaft, frame rails, fuel tank, and rear axle. Maintain minimum 1 inch clearance from all components. Ensure tailpipe exits properly through the rear bumper opening with centered alignment.
15
Torque all fasteners
Starting at the front connection, torque flange bolts to specification in a cross pattern if multiple bolts are present. Then torque the rear muffler clamp bolts. Remove the supporting floor jack from under the muffler.
Torque spec
Muffler Clamps55 Nm (41 lb-ft)

Reassembly

Visually verify all clamps and flange connections are tight with no gaps
Confirm exhaust hangers are properly seated and supporting the system with even weight distribution
Check that exhaust system has proper clearance from all components throughout its length
Lower vehicle from jack stands and remove all tools from under vehicle

Verification

Start engine and allow to idle, listening for exhaust leaks at all connection points (hissing or ticking sounds indicate leaks)
With engine running, visually inspect all connections for exhaust gas escaping
Rev engine to 2000-2500 RPM and verify no unusual vibrations or rattling from exhaust system
Check that exhaust smell is present only at tailpipe exit, not from underneath vehicle
Perform test drive and verify no contact noises during acceleration, deceleration, or over bumps
After test drive, re-inspect all connections while exhaust is hot to verify no leaks developed under thermal expansion