This procedure covers the removal and replacement of the muffler assembly on a 2021-2024 Ford F-150 with the 3.5L EcoBoost V6 engine, including disconnecting exhaust clamps, hangers, and associated hardware.

Warnings

Tools required

Parts

• Muffler assembly × 1 — Use OEM specification or equivalent
• Exhaust gasket (if flange connection) × 1 — Use OEM specification
• Rubber exhaust hangers (if damaged) × 2 — Replace as needed

Preparation

1. Ensure the exhaust system has cooled completely for at least 1 hour after engine operation.
2. Park vehicle on level ground and apply parking brake.
3. Place wheel chocks behind the front wheels.
4. Raise the rear of the vehicle using a floor jack at the rear axle or designated lift points.
5. Support the vehicle securely on jack stands rated for the vehicle weight.
6. Spray all exhaust fasteners (clamps, flanges, hangers) with penetrating oil and allow to soak for 15-20 minutes.
7. Inspect the exhaust system from underneath to identify muffler location, connection points, and hanger locations.

Procedure

1. 1

   Locate and inspect muffler assembly
   Position yourself under the vehicle with adequate lighting. Locate the muffler assembly between the resonator (forward) and tailpipe (rearward). Identify the inlet connection (clamp or flange), outlet connection, and rubber hanger mounting points. Note the routing of the exhaust system for proper reinstallation.
2. 2

   Disconnect rear exhaust hanger
   Locate the rearmost rubber exhaust hanger supporting the muffler or tailpipe connection. Using a pry bar or exhaust hanger tool, carefully pry the exhaust pipe eyelet out of the rubber hanger mounted to the vehicle frame. Work the hanger off by pushing the pipe to one side while pulling away from the hanger. Inspect rubber hanger for cracks or deterioration and replace if damaged.
3. 3

   Disconnect forward exhaust hanger
   Locate the forward rubber exhaust hanger(s) supporting the muffler inlet. Using the same technique, carefully pry the exhaust pipe eyelet out of the rubber hanger. The muffler should now be supported only by its inlet and outlet connections. Have a helper support the muffler weight or use a transmission jack to prevent it from dropping.
4. 4

   Remove outlet connection
   At the muffler outlet (toward rear of vehicle), identify the connection type. If using a band clamp, loosen the clamp bolt(s) completely and remove the clamp. If using a flange connection, remove the flange bolts. Separate the connection by wiggling and pulling the pipes apart. You may need to rotate or twist slightly to break the seal.
   Torque spec

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

   Remove inlet connection
   At the muffler inlet (toward front of vehicle), identify the connection type. If using a band clamp, loosen and remove the clamp bolt(s) completely. If using a flange connection with gasket, remove all flange bolts while supporting the muffler. Carefully separate the connection, working the muffler pipe out of the inlet pipe or resonator connection.
   Torque spec

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

   Remove muffler assembly
   With both connections freed, carefully lower and maneuver the muffler assembly out from under the vehicle. The assembly may need to be rotated or angled to clear frame components, fuel tank, or rear axle. Remove carefully to avoid damaging brake lines or fuel lines.
7. 7

   Clean connection surfaces
   Using a wire brush, thoroughly clean the inlet and outlet pipe surfaces where the new muffler will connect. Remove all carbon buildup, rust, and old gasket material from flange surfaces if applicable. Clean the exhaust pipe eyelets that mount to rubber hangers. Inspect connecting pipes for damage, excessive rust, or holes that may require repair.
8. 8

   Prepare new muffler
   Unpack the new muffler assembly and verify it matches the original in terms of inlet/outlet diameter, overall length, and hanger locations. If flange connections are used, install new exhaust gasket(s) onto the muffler inlet/outlet flanges. Apply anti-seize compound to all bolt threads that will be used for flange connections.
9. 9

   Position new muffler
   Carefully maneuver the new muffler assembly into position under the vehicle, following the reverse path of removal. Align the inlet connection first, sliding the pipe into position but do not fully tighten. Support the muffler with a transmission jack or have a helper hold it in position.
10. 10

    Connect muffler inlet
    Align the muffler inlet with the forward exhaust pipe or resonator outlet. For clamp connections, slide the inlet pipe into the connecting pipe approximately 2-3 inches, position the band clamp over the joint, and hand-tighten the clamp bolts. For flange connections, align the flanges with the gasket in place and start all flange bolts hand-tight.
    Torque spec

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

    Connect muffler outlet
    Align the muffler outlet with the rear tailpipe connection. For clamp connections, slide the pipes together approximately 2-3 inches, position the band clamp over the joint, and hand-tighten. For flange connections, align flanges with gasket and start all bolts hand-tight. Ensure proper alignment before final tightening.
    Torque spec

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

    Install exhaust hangers
    Working from front to rear, reconnect each rubber exhaust hanger. Apply a small amount of soapy water or silicone lubricant to the pipe eyelet to ease installation. Push the pipe toward the hanger and work the eyelet into the rubber hanger slot. Ensure each hanger is fully seated and the exhaust system has proper clearance from the vehicle underbody, fuel tank, and rear axle.
13. 13

    Align and adjust exhaust system
    With all connections hand-tight and hangers installed, check the entire exhaust system alignment. Verify minimum 1-inch clearance between exhaust components and fuel tank, brake lines, body panels, and frame. Adjust as needed by loosening clamps slightly and repositioning. Ensure the tailpipe exits properly at the rear bumper.
14. 14

    Torque all fasteners
    Working from front to rear, torque all exhaust connections to specification. For muffler clamp connections, torque clamp bolts to 55 Nm (41 lb-ft). For flange bolt connections (if applicable), apply anti-seize to threads and torque to 45 Nm (33 lb-ft). Double-check that all fasteners are tightened and no connections are loose.
    Torque spec

    Muffler Clamps55 Nm (41 lb-ft)

Reassembly

1. Verify all exhaust clamps and flange bolts are torqued to specification.
2. Confirm all rubber exhaust hangers are properly seated and supporting the system.
3. Check that exhaust system has adequate clearance from all vehicle components including fuel tank, brake lines, driveshaft, and body panels.
4. Lower the vehicle from jack stands carefully and remove jack stands and wheel chocks.

Verification

• Start the engine and allow it to idle. Listen for any exhaust leaks at the muffler inlet and outlet connections. A hissing or ticking sound indicates a leak that requires retightening or gasket replacement.
• With the engine running, carefully feel around connection points (without touching hot components) for escaping exhaust gases.
• Perform a test drive and listen for any rattling, buzzing, or contact between the exhaust system and vehicle body or frame, especially over bumps.
• After test drive, re-inspect all connections and hangers from underneath to ensure nothing has shifted or loosened.
• Verify tailpipe position and ensure exhaust exits properly without contacting the rear bumper.

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