This procedure covers the removal and replacement of the tail pipe section on a 2015-2020 Ford F-150 with the 5.0L Coyote V8 engine, including disconnecting exhaust hangers and flange connections.

Warnings

Tools required

Parts

• Tail pipe assembly × 1 — Use OEM specification
• Exhaust flange gasket × 1 — Use OEM specification
• Exhaust hanger insulators (if worn) × 2 — Use OEM specification

Preparation

1. Ensure engine and exhaust system are completely cool to the touch
2. Park vehicle on level surface and engage parking brake
3. Raise rear of vehicle using floor jack and support securely on jack stands at frame rails
4. Spray all exhaust flange bolts and hanger bolts with penetrating oil and allow 15-30 minutes soak time if components show corrosion

Procedure

1. 1

   Inspect exhaust routing and connections
   Locate the tail pipe section which extends from the muffler outlet to the rear bumper exit. Identify the flange connection point at the muffler outlet and note the rubber hanger locations supporting the tail pipe (typically 2 hangers on this section).
2. 2

   Support tail pipe section
   Position a jack stand or have an assistant support the weight of the tail pipe to prevent it from dropping when disconnected. The pipe should be supported near the muffler connection point to prevent stress on components.
3. 3

   Remove flange bolts at muffler connection
   Using a 15mm wrench and socket, remove the two bolts securing the tail pipe flange to the muffler outlet flange. Work bolts back and forth if corroded rather than forcing to prevent breakage. Remove and discard the old gasket.
   Torque spec

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

   Disconnect first rubber hanger
   Locate the first rubber hanger insulator nearest the muffler connection. Use a pry bar or push the pipe to one side to disengage the hanger rod from the rubber insulator grommet. A twisting motion while pulling helps separate stubborn hangers.
5. 5

   Disconnect remaining hangers
   Move toward the rear of the vehicle and disconnect the remaining rubber hanger(s) in the same manner. The tail pipe should now be free to remove. Inspect rubber insulators for cracking or deterioration and replace if necessary.
6. 6

   Remove tail pipe
   Carefully lower and remove the tail pipe assembly from under the vehicle. Take care not to damage brake lines, fuel lines, or wiring during removal.
7. 7

   Clean muffler flange surface
   Use a wire brush to thoroughly clean the muffler outlet flange surface, removing all old gasket material, rust, and debris. The flange must be clean and flat for proper sealing of the new gasket.
8. 8

   Prepare new tail pipe
   Clean the flange surface on the new tail pipe assembly with a wire brush. Apply a thin, even coat of anti-seize compound to the threads of the exhaust flange bolts, being careful not to get anti-seize on the gasket sealing surfaces.
9. 9

   Install new exhaust flange gasket
   Position the new exhaust flange gasket on the muffler outlet flange. Ensure the gasket is properly aligned with bolt holes and sealing surface.
10. 10

    Position new tail pipe
    Lift the new tail pipe into position, aligning the flange with the muffler outlet. Engage the hanger rods into the rubber insulators, starting with the hanger closest to the muffler connection. You may need to use a pry bar to stretch the rubber insulators over the hanger rods.
11. 11

    Install and torque flange bolts
    Install the two exhaust flange bolts finger-tight, ensuring the gasket remains properly positioned. Using a torque wrench, tighten the bolts in a cross pattern to the specified torque of 45.0 Nm (33.0 lb-ft).
    Torque spec

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

    Verify tail pipe alignment and clearance
    Check that the tail pipe exit is properly positioned at the rear bumper cutout and that there is adequate clearance between the tail pipe and all surrounding components including the spare tire, frame rails, hitch receiver (if equipped), and rear axle. Adjust hanger positions if needed to achieve proper alignment. The pipe should hang straight with no contact points.

Reassembly

1. Ensure all rubber hangers are fully seated and supporting the tail pipe weight evenly
2. Verify minimum 1/2 inch clearance between tail pipe and all body/chassis components throughout full suspension travel
3. Double-check torque on all flange bolts

Verification

• Lower vehicle from jack stands and start engine
• Listen for exhaust leaks at the flange connection while engine is running - there should be no hissing or ticking sounds
• Check that exhaust exits properly from tail pipe and there is no smoke or fumes escaping from flange connection
• Take a short test drive and verify no rattles, vibrations, or exhaust odor in cabin
• Re-inspect flange connection and hangers after test drive to ensure everything remains properly seated

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