This procedure covers the removal and replacement of the muffler assembly on a 2015-2020 Ford F-150 with the 5.0L Coyote V8 engine.

Warnings

Tools required

Parts

• Muffler assembly × 1 — Use OEM specification or aftermarket equivalent
• Muffler gasket (if applicable) × 1 — Use OEM specification
• Rubber exhaust hangers × 2 — Replace if damaged

Preparation

1. Ensure the exhaust system has cooled completely (minimum 1 hour after engine shutdown)
2. Park vehicle on level ground and engage parking brake
3. Apply penetrating oil to all muffler clamps, flange bolts, and hanger bolts if corrosion is present
4. Raise vehicle using floor jack and support securely on jack stands at the frame rails behind the rear axle
5. Verify adequate working clearance beneath the vehicle (minimum 24 inches recommended)

Procedure

1. 1

   Locate and inspect muffler assembly
   Position yourself under the vehicle and locate the muffler assembly positioned forward of the rear axle. Inspect all connection points including the inlet flange or clamp connection to the mid-pipe, outlet connection to the tailpipe, and rubber hangers supporting the muffler. Note the configuration for reassembly.
2. 2

   Support the muffler
   Use a floor jack or have an assistant support the weight of the muffler assembly to prevent it from falling when fasteners are removed. Position support near the center of the muffler body.
3. 3

   Disconnect outlet connection
   Locate the connection between the muffler outlet and the tailpipe. If equipped with a clamp connection, loosen and remove the muffler clamp bolts. If equipped with a flange connection, remove the flange bolts. Separate the connection using a pry bar if necessary, being careful not to damage the tailpipe.
   Torque spec

   Muffler Clamps55 Nm (41 lb-ft)
4. 4

   Disconnect inlet connection
   Locate the connection between the mid-pipe and muffler inlet. Remove the clamp bolts or flange bolts as applicable to your vehicle configuration. Use a pry bar or exhaust separator tool to separate the connection if the pipes are seized together.
   Torque spec

   Muffler Clamps55 Nm (41 lb-ft)
5. 5

   Remove exhaust hangers
   Locate the rubber exhaust hangers supporting the muffler assembly (typically two hangers). Use a pry bar or pull firmly to disconnect the metal hooks from the rubber grommets. If hanger bolts secure brackets to the frame or muffler, remove these bolts.
   Torque spec

   Hanger Bracket Bolts25 Nm (18 lb-ft)
6. 6

   Remove muffler assembly
   With all connections and hangers disconnected, carefully lower the muffler assembly and remove it from beneath the vehicle. Inspect the inlet and outlet pipes on the vehicle for damage or excessive corrosion.
7. 7

   Clean connection surfaces
   Use a wire brush to clean all mating surfaces on the mid-pipe and tailpipe where they connect to the new muffler. Remove rust, carbon deposits, and old gasket material. Ensure surfaces are clean and smooth for proper sealing.
8. 8

   Prepare new muffler
   Unpack the new muffler assembly and verify it matches the original configuration. If flange connections are used, apply anti-seize compound to the flange bolt threads. Install new gaskets on flange connections if applicable.
9. 9

   Position new muffler
   With assistance or using a jack for support, position the new muffler assembly under the vehicle. Align the inlet and outlet pipes with their respective connections. Ensure proper orientation with any directional flow arrows pointing toward the rear of the vehicle.
10. 10

    Connect exhaust hangers
    Reconnect the metal hanger hooks to the rubber grommets. Install new rubber hangers if the originals are torn or deteriorated. If bracket bolts were removed, reinstall and torque them to specification. Use a pry bar or rubber mallet to assist with hanger installation if needed.
    Torque spec

    Hanger Bracket Bolts25 Nm (18 lb-ft)
11. 11

    Connect inlet pipe
    Align the muffler inlet with the mid-pipe connection. Install the appropriate clamp or flange connection. For flange connections, ensure the gasket is properly seated. Start all fasteners finger-tight before final torquing to allow for alignment adjustments.
    Torque spec

    Muffler Clamps55 Nm (41 lb-ft)
12. 12

    Connect outlet pipe
    Align the muffler outlet with the tailpipe connection. Install the appropriate clamp or flange connection. Verify the tailpipe exit location is correct and matches the original position. Start all fasteners finger-tight.
    Torque spec

    Muffler Clamps55 Nm (41 lb-ft)
13. 13

    Align and verify clearances
    Before final tightening, verify the entire exhaust system has adequate clearance from the frame, fuel tank, spare tire, and rear axle. Check for at least 1 inch clearance at all points. Adjust as necessary by loosening hangers and shifting the system.
14. 14

    Torque all fasteners
    Using a torque wrench, tighten all clamp bolts, flange bolts, and hanger fasteners to the specified torque values in the following sequence: inlet connection, outlet connection, then hanger bolts. Work from front to rear of the exhaust system.
    Torque spec

    Muffler Clamps55 Nm (41 lb-ft)

    Hanger Bracket Bolts25 Nm (18 lb-ft)

Reassembly

1. Double-check all fasteners are torqued to specification
2. Verify no tools or parts were left under the vehicle
3. Lower vehicle from jack stands carefully

Verification

• Start the engine and listen for exhaust leaks at all connection points (hissing or ticking sounds indicate leaks)
• With engine running, visually inspect all connections for escaping exhaust gases
• Rev engine to 2500 RPM and verify no unusual vibrations or rattling from exhaust system
• Check exhaust outlet to confirm proper flow and verify tailpipe position has not shifted
• After a short test drive, re-inspect all connections and clearances with the system hot
• Listen for any rattles or contact points during driving that may require adjustment

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