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

Warnings

Tools required

Parts

• Intermediate pipe assembly × 1 — Use OEM specification or aftermarket equivalent
• Exhaust flange gaskets × 2 — Use OEM specification
• Exhaust hangers (if damaged) × 1 — Use OEM specification

Preparation

1. Ensure engine and exhaust system are completely cool to the touch
2. Park vehicle on level surface and set parking brake
3. Spray all exhaust flange bolts, hanger bolts, and O2 sensor connections with penetrating oil if corrosion is visible
4. Raise vehicle and secure on jack stands at all four corners for stability
5. Allow vehicle to settle on jack stands and verify stability before working underneath

Procedure

1. 1

   Disconnect oxygen sensors
   Locate the oxygen sensors on the intermediate pipe section. Disconnect the electrical connectors by pressing the release tab and pulling apart. If removing sensors for reuse, use a 22mm oxygen sensor socket to carefully unthread them. If replacing the intermediate pipe with a new assembly that includes sensor bungs, you may leave sensors installed temporarily.
2. 2

   Remove heat shields if present
   Locate any heat shields attached to or near the intermediate pipe. Remove the heat shield mounting bolts using a 10mm socket. Set heat shields aside for reinstallation. Note the position and orientation of each shield for proper reassembly.
   Torque spec

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

   Disconnect intermediate pipe from catalytic converters
   Locate the forward flange connection where the intermediate pipe connects to the catalytic converter outlets. Using a 15mm socket, remove the flange bolts securing this connection. There are typically 2 bolts per flange connection. Support the intermediate pipe weight with one hand while removing the final bolt. Separate the flange and remove the old gasket.
   ⚠Bolts may break due to corrosion. If a bolt breaks, you may need to drill out the stud and install a new one.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
4. 4

   Disconnect intermediate pipe from rear exhaust section
   Move to the rear connection point where the intermediate pipe connects to the muffler or rear exhaust section. Using a 15mm socket, remove the exhaust flange bolts at this connection. Support the pipe to prevent it from falling when the connection is released. Separate the flange and remove the old gasket.
   Torque spec

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

   Remove rubber exhaust hangers
   Locate the rubber exhaust hangers supporting the intermediate pipe. There are typically 1-2 hangers on this section. Use a pry bar or exhaust hanger removal tool to work the exhaust pipe loops out of the rubber hangers. Apply a twisting and pulling motion. Do not cut hangers unless they are damaged and being replaced.
6. 6

   Remove intermediate pipe assembly
   With all connections and hangers released, carefully lower the intermediate pipe assembly from the vehicle. The pipe may be heavy and awkward to maneuver around the frame and driveshaft. Rotate and angle the pipe as needed to clear all obstacles. Have an assistant help guide the pipe out if necessary.
   ⚠Watch for sharp edges on the exhaust pipe and surrounding components. Wear gloves to protect hands.
7. 7

   Prepare flange surfaces
   With the intermediate pipe removed, use a wire brush to thoroughly clean the mating surfaces on both the catalytic converter outlet flanges and the rear exhaust inlet flange. Remove all old gasket material, carbon buildup, and corrosion. Clean surfaces ensure proper sealing with new gaskets.
8. 8

   Transfer oxygen sensors if necessary
   If the new intermediate pipe does not include oxygen sensors, remove the sensors from the old pipe using a 22mm oxygen sensor socket. Apply anti-seize compound only to the threads (not the sensor tip) and thread the sensors into the new pipe bungs by hand, then torque to specification.
   ⚠Never apply anti-seize to the oxygen sensor tip as this will contaminate the sensor and cause false readings.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
9. 9

   Install new intermediate pipe
   Position the new intermediate pipe into place by maneuvering it up and around obstacles. Start by inserting the pipe loops into the rubber exhaust hangers. With the hangers supporting the weight, align the forward flange with the catalytic converter outlets. Install new exhaust gaskets at both flange connections.
10. 10

    Connect forward flange to catalytic converters
    With the new gasket in place, align the intermediate pipe forward flange with the catalytic converter outlet flange. Apply anti-seize compound to the flange bolt threads. Start all bolts by hand, then tighten in a cross pattern to ensure even compression. Torque to specification using a torque wrench.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
11. 11

    Connect rear flange to exhaust system
    Position the new gasket at the rear flange connection. Align the intermediate pipe rear flange with the muffler or rear exhaust inlet flange. You may need to adjust the position slightly by moving the pipe within the rubber hangers. Apply anti-seize to bolt threads, start all bolts by hand, then tighten in a cross pattern and torque to specification.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
12. 12

    Reconnect oxygen sensors
    Locate the oxygen sensor electrical connectors and reconnect them to the vehicle wiring harness. Ensure each connector clicks securely into place. Route the sensor wiring away from heat sources and moving components, using factory wire clips if present.
13. 13

    Reinstall heat shields
    If heat shields were removed, position them in their original locations and orientations. Install the heat shield bolts and torque to specification. Ensure shields do not contact the exhaust pipe directly and have proper clearance.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Verify all exhaust hangers are properly seated and supporting the exhaust system
2. Check that all flange connections are tight and gaskets are properly compressed
3. Ensure oxygen sensor wiring is routed away from hot exhaust components and not stretched or pinched
4. Confirm all heat shields are securely mounted with proper clearance

Verification

• Lower vehicle from jack stands and start engine while in a well-ventilated area or outdoors
• Listen for exhaust leaks at all flange connections during cold start and warm-up
• Visually inspect all connections for signs of exhaust gas leakage (soot or smoke)
• Check that exhaust system is not contacting frame, driveshaft, or body components during idle
• Take a short test drive and verify no abnormal exhaust noise, rattles, or vibrations
• After test drive, re-inspect all flange connections and hangers while exhaust is warm but not hot
• Check for proper oxygen sensor operation by verifying no check engine light and monitoring sensor data if scan tool is available

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