Exhaust Hangers

This procedure covers the inspection and replacement of rubber exhaust hangers on the 2015-2020 Ford F-150 5.0L V8, which support the exhaust system and isolate vibration from the chassis.

Warnings

Tools required

Parts

• Exhaust hanger (rubber isolator) × 1 — Use OEM specification or Dorman 35527

Preparation

1. Park vehicle on level, solid surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Allow exhaust system to cool completely (minimum 1 hour after engine operation)
4. Identify which hanger(s) require replacement by visual inspection for cracks, tears, or excessive deterioration
5. Spray hanger mounting points with penetrating oil if corrosion is present

Procedure

1. 1

   Raise and support vehicle
   Raise the rear of the vehicle using a floor jack at the rear axle differential housing. Place jack stands under the frame rails behind the cab. Lower vehicle onto jack stands and verify stability before working underneath.
2. 2

   Locate failed exhaust hanger
   Position yourself under the vehicle and locate the exhaust hanger requiring replacement. The F-150 5.0L V8 typically has 4-6 hangers along the exhaust system from the catalytic converters to the tailpipe. Common failure points are at the muffler and tailpipe locations due to heat and vibration.
3. 3

   Support exhaust pipe
   Have an assistant support the exhaust pipe near the hanger location, or use a transmission jack or block of wood on a floor jack to gently support the exhaust system weight. This prevents excessive stress on adjacent hangers during removal.
4. 4

   Remove exhaust pipe from hanger
   Using a flathead screwdriver or small pry bar, carefully pry the exhaust pipe mounting tab out of the rubber hanger isolator. Work the tab side-to-side while applying gentle outward pressure. Apply penetrating oil if the rubber has bonded to the metal tab. Do not use excessive force as this may bend the exhaust mounting bracket.
5. 5

   Remove hanger from frame bracket
   If the hanger is mounted with bolts to the frame bracket, use a ratchet and appropriate socket to remove the mounting hardware. Most F-150 hangers slot into frame-mounted brackets and can be pulled out once the exhaust pipe is free. Twist and pull the rubber hanger downward to remove it from the frame bracket slot.
   Torque spec

   Hanger Bolts26 Nm (19 lb-ft)
6. 6

   Clean mounting points
   Use a wire brush to clean the frame bracket and exhaust pipe mounting tab. Remove rust, rubber residue, and debris from both surfaces. Inspect the metal mounting tab on the exhaust pipe for cracks or damage. If the tab is severely corroded or bent, the exhaust component may need replacement.
7. 7

   Install new hanger to frame bracket
   Position the new rubber hanger into the frame bracket slot or align with bolt holes. If using bolted hangers, start bolts by hand and tighten to specification. Ensure the hanger is fully seated and oriented correctly before proceeding. The hanger should hang vertically with the mounting hole or slot facing the exhaust pipe tab.
   Torque spec

   Hanger Bolts26 Nm (19 lb-ft)
8. 8

   Install exhaust pipe into new hanger
   Apply a small amount of soapy water or silicone spray to the exhaust pipe mounting tab to ease installation. Align the exhaust pipe tab with the rubber hanger opening. Push the tab into the hanger using steady pressure, working it side-to-side if necessary. A flathead screwdriver can be used to stretch the rubber slightly, but avoid cutting or tearing the new hanger.
9. 9

   Verify exhaust system alignment
   Remove any supporting jacks or blocks from under the exhaust system. Visually inspect the entire exhaust system to ensure it hangs evenly and does not contact the frame, driveshaft, fuel tank, or rear axle. There should be at least 1 inch of clearance from all components. Adjust hanger positions if necessary to center the exhaust system.
10. 10

    Lower vehicle and perform road test
    Raise vehicle slightly with floor jack, remove jack stands, and lower vehicle completely to the ground. Start the engine and listen for exhaust leaks or abnormal vibration. Perform a test drive and verify no rattling, buzzing, or vibration is felt through the cab or bed. Re-inspect hanger installation after test drive to ensure proper seating.

Reassembly

1. No disassembly of other components required for this procedure

Verification

• Start engine and verify no exhaust leaks are present at flanges or connections near the replaced hanger
• Confirm exhaust system hangs level with adequate clearance from frame, driveshaft, and fuel tank (minimum 1 inch)
• Test drive vehicle and verify no abnormal vibration, rattling, or buzzing from exhaust system
• Visually inspect new hanger after test drive to confirm it remains properly seated in frame bracket and exhaust pipe tab

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