This procedure covers the removal and replacement of the tail pipe assembly on a 2015-2020 Ford F-150 with the 3.5L EcoBoost engine, including disconnecting hangers and exhaust flange connections.

Warnings

Tools required

Parts

• Tail pipe assembly × 1 — Use OEM specification
• Exhaust flange gasket × 1 — Use OEM specification
• Rubber exhaust hangers × 2 — Replace if damaged

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow exhaust system to cool completely for at least 2 hours if engine has been running
3. Raise rear of vehicle using floor jack and support securely on jack stands rated for vehicle weight
4. Spray all exhaust flange bolts and hanger bolts with penetrating oil and allow to soak for 15-30 minutes
5. Visually inspect tail pipe routing and identify all hanger points and flange connection

Procedure

1. 1

   Support tail pipe assembly
   Position a jack stand or have an assistant support the tail pipe assembly to prevent it from falling once disconnected. The tail pipe extends from behind the muffler to the rear bumper and has two rubber hanger mounts.
2. 2

   Remove rear exhaust hanger
   Locate the rearmost rubber exhaust hanger near the bumper. Use a pry bar or pull firmly to disconnect the tail pipe from the rubber hanger mount. The hanger isolator may be stiff and require significant force to separate.
   ℹ️Inspect rubber hangers for cracking or deterioration. Replace if damaged to prevent future exhaust rattles.
3. 3

   Remove middle exhaust hanger
   Locate the second rubber exhaust hanger approximately midway along the tail pipe. Disconnect the tail pipe from this hanger mount using the same method as the rear hanger.
4. 4

   Remove exhaust flange bolts
   Locate the flange connection between the tail pipe and the muffler outlet pipe. Remove the two or three flange bolts using a 15mm socket. Support the tail pipe weight as you remove the final bolt to prevent the assembly from dropping.
   ⚠If bolts are severely corroded and break off, the muffler studs may need to be drilled out and replaced. Consider heating bolts with a torch if they will not loosen.
   Torque spec

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

   Remove tail pipe assembly
   Carefully lower and remove the tail pipe assembly from the vehicle. The pipe exits near the rear passenger side of the vehicle. Maneuver it clear of the rear axle and suspension components.
6. 6

   Clean flange mating surface
   Use a wire brush to thoroughly clean the muffler outlet flange surface, removing all old gasket material, rust, and debris. The flange surface must be clean and flat to ensure a proper seal with the new gasket.
7. 7

   Install new flange gasket
   Position the new exhaust flange gasket onto the muffler outlet flange. Ensure the gasket is properly aligned with all bolt holes. Apply a thin coat of anti-seize compound to the flange bolt threads.
8. 8

   Install tail pipe assembly
   Lift the new or replacement tail pipe into position and align the inlet flange with the muffler outlet flange. Insert the tail pipe hangers into the rubber isolator mounts, starting with the front hanger first. You may need an assistant to hold the pipe in position.
9. 9

   Install and torque flange bolts
   Hand-thread all flange bolts through the tail pipe flange and into the muffler flange. Once all bolts are started, tighten them in a cross pattern to the specified torque of 45 Nm (33 lb-ft) using a torque wrench.
   ℹ️Use anti-seize compound on bolt threads as specified to prevent future corrosion and enable easier removal.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
10. 10

    Verify hanger engagement
    Confirm both rubber exhaust hangers are fully seated and the tail pipe is properly supported. The pipe should have minimal side-to-side movement but allow some flex for thermal expansion. Adjust hanger position if necessary.
11. 11

    Check tail pipe clearance
    Verify the tail pipe has adequate clearance from the rear axle, fuel tank, spare tire, and body panels. There should be at least 1 inch clearance from all components. Adjust hangers if pipe is too close to any component.

Reassembly

1. Ensure all exhaust hangers are properly engaged and tail pipe is securely mounted
2. Verify flange bolts are torqued to specification and gasket is properly sealed
3. Lower vehicle from jack stands and remove all tools from work area

Verification

• Start engine and listen for exhaust leaks at the flange connection. A hissing or ticking sound indicates a leak.
• With engine running, visually inspect the flange joint for any visible exhaust gases escaping
• Rev engine to 2000-2500 RPM and verify no excessive exhaust rattles or contact with suspension or body
• After 10-15 minutes of running, re-check flange bolt torque when exhaust has warmed up (allow to cool slightly before touching)

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