This procedure covers the removal and replacement of the exhaust manifold on a 2021-2024 Ford F-150 with the 3.5L EcoBoost V6 engine, including turbocharger access and O2 sensor handling.

Warnings

Tools required

Parts

• Exhaust manifold gasket × 1 — Use OEM Ford specification
• Turbocharger to exhaust manifold gasket × 1 — Use OEM Ford specification
• Exhaust flange gasket × 1 — Use OEM Ford specification
• Heat shield gasket (if equipped) × 1 — Use OEM Ford specification
• Exhaust manifold studs (if damaged) × 8 — Use OEM Ford specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely (minimum 2 hours after last operation)
3. Disconnect negative battery cable and wait 10 minutes for system capacitors to discharge
4. Remove engine cover by pulling upward on four retention points
5. Spray all exhaust fasteners with penetrating oil and allow to soak minimum 30 minutes
6. Raise and support vehicle on jack stands if accessing from below
7. Remove plastic wheelhouse liner for improved access (passenger side)

Procedure

1. 1

   Remove oxygen sensor
   Disconnect O2 sensor electrical connector by depressing tab and pulling apart. Use O2 sensor socket or 22mm wrench to remove sensor from exhaust manifold by turning counterclockwise. Sensor may require significant force if not recently serviced. Inspect threads and replace sensor if damaged.
   Torque spec

   O2 Sensor55 Nm (40 lb-ft)
2. 2

   Disconnect turbocharger oil feed and drain lines
   Locate turbocharger oil feed line at top of turbo and oil drain line at bottom. Place drain pan beneath turbo to catch residual oil. Remove oil feed line banjo bolt and oil drain line fasteners. Cap or plug openings immediately to prevent contamination. Inspect lines for damage or restrictions.
   ⚠Expect approximately 2-4 oz of oil to drain from lines. Do not allow dirt or debris to enter turbocharger or engine oil passages.
   Torque spec

   Mounting Bolts54 Nm (40 lb-ft)
3. 3

   Remove heat shield
   Remove heat shield mounting bolts securing shield to exhaust manifold and turbocharger. There are typically 3-5 bolts depending on configuration. Carefully remove heat shield, noting any spacers or washers for reinstallation. Inspect shield for cracks or excessive corrosion.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
4. 4

   Disconnect exhaust downpipe
   Support downpipe with jack stand or wire to prevent stress on remaining connections. Remove exhaust flange bolts connecting turbocharger outlet to downpipe (typically 3 bolts in triangular pattern). Separate flange connection and lower downpipe slightly. Remove and discard old gasket.
   ℹ️Verify torque sequence with Ford service manual before reassembly. Improper sequence can cause exhaust leaks.
   Torque spec

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

   Remove turbocharger mounting hardware
   Disconnect wastegate actuator rod from turbocharger linkage if applicable. Remove electrical connectors from any sensors on turbocharger assembly. Remove turbocharger mounting bolts securing turbo to exhaust manifold (typically 4 bolts). Do not remove turbocharger completely unless replacement is required.
   Torque spec

   Electrical Connector Bolts8 Nm (6 lb-ft)

   Exhaust Flange Bolts45 Nm (33 lb-ft)
6. 6

   Separate turbocharger from manifold
   Carefully pull turbocharger away from exhaust manifold, breaking gasket seal. Support turbocharger weight to prevent damage to oil lines or mounting studs. If turbo remains attached, use penetrating oil on studs and allow additional soak time. Remove and discard turbocharger gasket.
   ⚠Turbocharger assembly weighs approximately 15-20 lbs. Ensure secure support before releasing mounting bolts.
7. 7

   Remove exhaust manifold nuts
   Working from the hottest area (center cylinders) toward cooler areas (outer cylinders), remove all exhaust manifold mounting nuts. There are 8 nuts total securing manifold to cylinder head. Use universal joint adapters to access difficult fasteners. If studs break, mark locations for extraction or replacement.
   ⚠Work hot-to-cold pattern as specified to reduce stud breakage risk. If stud breaks, it must be extracted before reinstallation.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
8. 8

   Remove exhaust manifold
   Carefully work exhaust manifold free from cylinder head studs. Manifold may require gentle prying to break gasket seal. Avoid damaging cylinder head gasket surface. Once free, remove manifold from engine bay. Inspect manifold for cracks, especially around turbo mounting flange and cylinder ports.
   ℹ️Exhaust manifold weighs approximately 20-25 lbs. Use proper lifting technique and avoid contact with fragile components.
9. 9

   Clean gasket surfaces
   Use plastic gasket scraper to remove all old gasket material from cylinder head and exhaust manifold mating surfaces. Do not use metal scrapers that could gouge aluminum surfaces. Clean surfaces with brake cleaner and lint-free cloth. Inspect cylinder head surface for warping or damage. Verify all manifold studs are intact and threads are clean.
   ⚠Do not allow gasket material or debris to fall into exhaust ports or cylinder head openings. Cover openings with clean rags during cleaning.
   Torque spec

   Gasket Surface Bolts23 Nm (17 lb-ft)
10. 10

    Install new exhaust manifold
    Position new or resurfaced exhaust manifold gasket onto cylinder head studs, ensuring proper orientation. Apply thin coat of anti-seize to exposed stud threads. Carefully position exhaust manifold onto studs and gasket. Start all manifold nuts by hand to ensure proper thread engagement before tightening.
    ℹ️Verify tightening sequence with Ford service manual. Typical pattern is center-out in crossing pattern to ensure even gasket compression.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
11. 11

    Reinstall turbocharger
    Install new turbocharger gasket onto exhaust manifold studs. Apply anti-seize to turbocharger mounting studs. Position turbocharger onto manifold, aligning all mounting holes. Install mounting bolts and tighten in crossing pattern. Reconnect wastegate actuator rod and electrical connectors.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)

    Electrical Connector Bolts8 Nm (6 lb-ft)
12. 12

    Reconnect exhaust downpipe
    Install new exhaust flange gasket between turbocharger outlet and downpipe. Align downpipe to turbo flange and install flange bolts with anti-seize on threads. Tighten bolts in specified sequence per service manual to ensure even gasket compression and prevent exhaust leaks.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
13. 13

    Install heat shield and reconnect turbo lines
    Position heat shield over exhaust manifold and turbocharger, ensuring proper alignment. Install heat shield bolts and tighten to specification. Remove caps from turbocharger oil feed and drain connections. Install new crush washers on banjo bolts. Reconnect oil feed and drain lines, ensuring proper routing and no contact with hot surfaces.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

    Mounting Bolts54 Nm (40 lb-ft)
14. 14

    Install oxygen sensor
    Apply anti-seize compound to O2 sensor threads (avoid getting compound on sensor tip). Thread sensor into exhaust manifold by hand until finger-tight. Use O2 sensor socket to tighten to specification. Reconnect O2 sensor electrical connector, ensuring positive lock engagement.
    ⚠Do not apply anti-seize to sensor tip or allow compound to contact sensing element. Contamination will cause sensor failure.
    Torque spec

    O2 Sensor55 Nm (40 lb-ft)

Reassembly

1. Reinstall wheelhouse liner and any removed splash shields
2. Lower vehicle from jack stands if raised
3. Reinstall engine cover by aligning mounting points and pressing down until clips engage
4. Reconnect negative battery cable
5. Check engine oil level and top off if needed due to turbo line disconnection

Verification

• Start engine and allow to idle, listening for exhaust leaks at manifold and flange connections
• Inspect all connection points for visible exhaust gas leakage (light smoke or soot patterns)
• Allow engine to reach operating temperature and verify no unusual noises from turbocharger area
• Check for oil leaks at turbocharger feed and drain line connections
• Use scan tool to verify O2 sensor is providing proper signal and no fault codes are present
• Perform test drive and verify normal turbocharger boost operation and no exhaust odors in cabin
• After 50-100 miles, re-inspect all exhaust connections and verify no leaks have developed

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