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

Warnings

Tools required

Parts

• Exhaust resonator assembly × 1 — Use OEM specification or aftermarket equivalent
• Exhaust flange gasket × 2 — Use OEM specification
• Exhaust clamps × 2 — Use OEM specification if replacing clamp-type connections
• Rubber exhaust hangers × 2 — Replace if damaged

Preparation

1. Park vehicle on level ground and apply parking brake
2. Chock the front wheels securely
3. Allow exhaust system to cool completely (minimum 1 hour after engine operation)
4. Raise rear of vehicle and support securely on jack stands rated for vehicle weight
5. Spray all exhaust fasteners, clamps, and flange bolts with penetrating oil and allow to soak for 15-30 minutes
6. Locate the resonator assembly in the mid-section of the exhaust system, between the Y-pipe and rear muffler

Procedure

1. 1

   Remove heat shields if present
   Inspect the resonator area for any heat shields attached to the undercarriage. If present, remove the heat shield mounting bolts using a socket wrench. These shields are typically secured to the frame or floor pan above the resonator.
   Torque spec

   Heat Shield Bolts16 Nm (12 lb-ft)
2. 2

   Disconnect oxygen sensor if equipped
   If an oxygen sensor is mounted on or near the resonator, disconnect the electrical connector by pressing the release tab and pulling apart. If the sensor must be removed from the resonator, use a 22mm oxygen sensor socket to remove it. Note the sensor position and orientation for reinstallation.
   ⚠Oxygen sensors are fragile. Do not drop or impact the sensor, and avoid contaminating the sensor tip with oil or debris.
   Torque spec

   O2 Sensor60 Nm (44 lb-ft)
3. 3

   Support the exhaust system
   Position a jack or exhaust support stand under the muffler assembly to support the weight of the exhaust system once the resonator is disconnected. Adjust height to prevent excessive stress on remaining hangers and connections.
   ⚠The exhaust system is heavy and awkward. Ensure adequate support is in place before loosening any fasteners.
4. 4

   Disconnect front connection
   Locate the connection between the Y-pipe (or intermediate pipe) and the front of the resonator. If using a flange connection, remove the flange bolts or nuts. If using a clamp connection, loosen and remove the exhaust clamp. Separate the joint carefully, rocking gently if needed.
   Torque spec

   Flange Bolts45 Nm (33 lb-ft)

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

   Disconnect rear connection
   Locate the connection between the rear of the resonator and the muffler assembly. If using a flange connection, remove the flange bolts or nuts. If using a clamp connection, loosen and remove the exhaust clamp. Separate the joint, noting the position of any gaskets.
   Torque spec

   Flange Bolts45 Nm (33 lb-ft)

   Exhaust Clamps55 Nm (41 lb-ft)
6. 6

   Remove exhaust hangers
   Locate the rubber exhaust hangers supporting the resonator. Using an exhaust hanger removal tool or by hand, pry the hangers off their mounting points on the frame or body. Pull the hanger loops off the metal hooks. Note the orientation of each hanger for reinstallation.
   ℹ️Applying soapy water or silicone spray to the rubber hangers can make removal easier.
7. 7

   Remove resonator assembly
   With all connections and hangers disconnected, carefully lower the resonator assembly from the vehicle. An assistant may be helpful due to the size and weight of the component. Inspect all connection points and hangers for damage or excessive wear.
8. 8

   Clean mating surfaces
   Use a wire brush to clean the flange surfaces on both the front and rear exhaust pipes. Remove all old gasket material, carbon buildup, and corrosion to ensure proper sealing. Inspect flanges for cracks, warping, or damage.
9. 9

   Install new resonator
   Position the new resonator assembly under the vehicle, aligning it with the front and rear exhaust connections. If replacing rubber hangers, install new hangers onto the resonator mounting points. Raise the resonator into position and engage the rubber hangers onto the frame hooks.
10. 10

    Connect front joint
    Install a new exhaust flange gasket if using a flange connection. Align the front of the resonator with the Y-pipe or intermediate pipe. Install flange bolts or exhaust clamp as applicable. Hand-tighten only at this stage to allow for alignment adjustment.
    Torque spec

    Flange Bolts45 Nm (33 lb-ft)

    Exhaust Clamps55 Nm (41 lb-ft)
11. 11

    Connect rear joint
    Install a new exhaust flange gasket if using a flange connection. Align the rear of the resonator with the muffler assembly inlet. Install flange bolts or exhaust clamp as applicable. Hand-tighten only at this stage.
    Torque spec

    Flange Bolts45 Nm (33 lb-ft)

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

    Align exhaust system
    With all connections hand-tight, check the entire exhaust system for proper alignment. Ensure adequate clearance between exhaust components and the fuel tank, driveshaft, frame, and body. Adjust as necessary by loosening hangers or shifting pipe positions.
    ⚠Minimum clearance of 1 inch should be maintained between exhaust components and fuel system components or heat-sensitive parts.
13. 13

    Torque all fasteners
    Once alignment is correct, torque all flange bolts and exhaust clamps to specification using a torque wrench. Torque in a cross-pattern for flange connections to ensure even loading and prevent leaks.
    Torque spec

    Flange Bolts45 Nm (33 lb-ft)

    Exhaust Clamps55 Nm (41 lb-ft)
14. 14

    Reinstall oxygen sensor and heat shields
    If an oxygen sensor was removed, apply anti-seize compound to the threads (avoid getting any on the sensor tip) and install it to specification. Reconnect the electrical connector. If heat shields were removed, reinstall them with mounting bolts torqued to specification.
    Torque spec

    O2 Sensor60 Nm (44 lb-ft)

    Heat Shield Bolts16 Nm (12 lb-ft)

Reassembly

1. Remove the exhaust support jack or stand
2. Verify all exhaust hangers are properly seated on their hooks
3. Verify all electrical connectors for oxygen sensors are fully engaged
4. Lower the vehicle from jack stands
5. Remove wheel chocks

Verification

• Start the engine and allow it to idle. Listen for exhaust leaks at the resonator connections. A hissing or ticking sound indicates a leak that must be corrected.
• Perform a visual inspection under the vehicle while the engine is running to check for visible exhaust leaks (look for escaping gases or soot buildup).
• With the engine running, verify that the exhaust system is not contacting the frame, body, fuel tank, or driveshaft.
• Take the vehicle for a test drive and listen for any unusual exhaust sounds, rattles, or vibrations.
• After test drive, perform a final inspection of all connections while the exhaust system is warm to check for any signs of leaks or loose fasteners.

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