Exhaust Pipe - Rear Section

This procedure covers removal and replacement of the rear exhaust section on a 2015-2020 Ford F-150 with 5.0L V8 Coyote engine, from the mid-pipe flange connection to the tailpipe outlets.

Warnings

Tools required

Parts

• Rear exhaust section assembly × 1 — Use OEM specification or aftermarket equivalent
• Exhaust flange gasket × 1 — 3-inch exhaust flange gasket
• Exhaust hanger insulators × 3 — Replace if torn or deteriorated
• Flange bolts and nuts × 4 — M10 x 1.5 exhaust flange hardware

Preparation

1. Ensure engine and exhaust system are completely cool to the touch
2. Park vehicle on level ground and engage parking brake
3. Spray all exhaust flange bolts and hanger mounting points with penetrating oil and allow to soak for 15-30 minutes
4. Raise vehicle using floor jack and support securely on jack stands at manufacturer-specified lift points
5. Verify adequate working clearance underneath vehicle (minimum 18 inches recommended)

Procedure

1. 1

   Inspect and document exhaust routing
   Before removal, visually inspect the rear exhaust section routing, noting hanger positions and any heat shield locations. Take photos if available to ensure proper reinstallation alignment. Check for clearance to fuel lines, brake lines, and spare tire carrier.
2. 2

   Remove heat shields if equipped
   If heat shields are present over the rear exhaust section, remove the mounting bolts using a 10mm socket. Heat shields are typically mounted above the rear axle and near the spare tire carrier. Set shields aside with hardware for reinstallation.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
3. 3

   Support rear exhaust section
   Position a floor jack or adjustable exhaust stand under the rear muffler section to support the weight. Raise slightly to relieve tension on the exhaust hangers but do not lift the vehicle. This prevents the exhaust from falling when disconnected.
   ⚠Maintain support on exhaust section throughout removal to prevent damage to oxygen sensors or wiring harnesses.
4. 4

   Disconnect mid-pipe flange connection
   Locate the flange connection between the mid-pipe and rear section, typically just behind the catalytic converters near the transmission crossmember. Using a 15mm socket, remove the flange bolts (typically 4 bolts). If bolts are severely corroded, apply additional penetrating oil and allow to soak. Work bolts back and forth if necessary. Retain old gasket for comparison with replacement.
   ⚠If flange bolts break during removal, the flange studs may need to be drilled out and replaced with new studs or through-bolts.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
5. 5

   Separate flange connection
   Once bolts are removed, carefully pull the rear section rearward to separate the flange connection. The pipes may be seized together by carbon buildup. Gently twist and pull while supporting the weight. Use a pry bar if necessary, taking care not to damage the mid-pipe flange surface.
   ℹ️Flange may require significant force to separate if vehicle has high mileage. Avoid bending or damaging flange surfaces.
6. 6

   Remove exhaust from front hanger
   Locate the front rubber hanger insulator where the rear section connects to the frame-mounted bracket (typically near the flange connection). Using a pry bar or exhaust hanger tool, pry the exhaust pipe loop from the rubber insulator. Spray with soapy water if needed to ease removal. Inspect rubber insulator for cracks or tears.
   ℹ️Exhaust hangers are under tension. Control the exhaust pipe as the hanger releases to prevent sudden movement.
7. 7

   Remove exhaust from middle hangers
   Continue moving rearward and remove the exhaust pipe from the remaining rubber hangers (typically 2 more hangers positioned along the frame rails). Use the same pry technique, working one hanger at a time while maintaining support on the exhaust assembly. Lower the jack slightly as needed to access hangers.
   ⚠Ensure exhaust section does not contact fuel lines, brake lines, or wiring during removal process.
8. 8

   Remove rear exhaust section
   With all hangers disconnected, carefully lower the rear exhaust section using the support jack. Maneuver the assembly rearward and downward, clearing the spare tire carrier, rear axle, and frame components. Remove from under vehicle. Inspect rubber hanger insulators on vehicle and replace any that show cracking, tearing, or deterioration.
9. 9

   Clean and prepare flange surfaces
   Using a wire brush and scraper, thoroughly clean the mid-pipe flange surface where the new rear section will connect. Remove all old gasket material, carbon deposits, and rust. The flange surface must be clean and flat for proper sealing. Inspect flange for warping or damage. Clean threads on flange studs or bolt holes if equipped.
   ℹ️A clean flange surface is critical for preventing exhaust leaks. Take time to ensure thorough cleaning.
10. 10

    Prepare new rear exhaust section
    Unpack new rear exhaust section and verify it matches the original in terms of inlet diameter, hanger positions, and tailpipe configuration. Install new rubber hanger insulators onto frame-mounted brackets if replacements are being used. Apply anti-seize compound to all flange bolt threads.
11. 11

    Install new rear exhaust section
    Position the new rear exhaust section under the vehicle and maneuver into approximate position, clearing the axle and spare tire carrier. Support with jack or exhaust stand. Begin by engaging the exhaust pipe loops into the rubber hanger insulators, starting from the rear and working forward. Use a pry bar or rubber mallet to assist engagement if needed. Leave hangers slightly loose initially for final alignment.
    ℹ️Do not fully seat exhaust in hangers yet. Leave some play for flange alignment in next step.
12. 12

    Connect flange and install new gasket
    Position new flange gasket between mid-pipe and rear section flanges. Align the flange bolt holes carefully. Slide the rear section forward to engage the flange connection. Insert flange bolts with anti-seize compound applied to threads. Thread all bolts by hand first to ensure proper alignment before tightening. Adjust hanger positions as needed to align flange without binding.
    ⚠Cross-threading flange bolts can damage expensive exhaust components. Always start bolts by hand and verify smooth threading.
13. 13

    Torque flange bolts
    Using a torque wrench and 15mm socket, tighten flange bolts in a crisscross pattern to ensure even gasket compression. Torque to specification in two stages: first to 30 Nm (22 lb-ft), then to final torque of 60 Nm (44 lb-ft). Verify gasket is seated evenly around the flange perimeter.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
14. 14

    Final alignment and hanger adjustment
    With flange connection secure, perform final alignment of the rear exhaust section. Check clearance to frame rails, spare tire carrier, fuel lines, brake lines, and body panels. Ensure minimum 1-inch clearance to all components. Adjust by repositioning exhaust in rubber hangers as needed. Verify tailpipe outlets are positioned symmetrically and at correct angle relative to rear bumper.
15. 15

    Reinstall heat shields
    If heat shields were removed, reinstall them in original positions using 10mm hardware. Ensure shields do not contact exhaust pipes directly and have proper clearance for thermal expansion. Torque heat shield bolts to specification.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Double-check all flange bolts are torqued to specification and anti-seize was applied
2. Verify exhaust hangers are fully engaged and rubber insulators are not twisted or damaged
3. Confirm minimum 1-inch clearance between exhaust and all fuel lines, brake lines, wiring, and body components
4. Ensure tailpipe outlets are aligned symmetrically and positioned correctly relative to bumper cutouts

Verification

• Start engine and listen for exhaust leaks at the flange connection. A leak will produce a distinct ticking or hissing sound that increases with engine RPM
• Verify no exhaust leaks are present by feeling for escaping gases around flange connection (use back of hand, not fingers)
• Check for abnormal vibration or rattling noises indicating contact between exhaust and chassis components
• Visually inspect from rear of vehicle to confirm tailpipes are level and symmetrically positioned
• Test drive vehicle and verify no exhaust drone, rattles, or contact noises under acceleration or deceleration
• After test drive, re-inspect flange connection and hanger points for any signs of movement or leakage
• If any exhaust leak is detected at flange, verify torque specification was met and gasket is properly seated

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