This procedure covers the removal and replacement of the exhaust resonator on a 2021-2024 Ford F-150 with the 3.5L EcoBoost V6 engine.

Warnings

Tools required

Parts

• Resonator assembly × 1 — Use OEM specification
• Exhaust gasket (flange to resonator) × 1 — Use OEM specification
• Exhaust gasket (resonator to muffler) × 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 (minimum 2 hours after last operation)
3. Raise vehicle using floor jack and support securely on jack stands at frame contact points
4. Spray all exhaust fasteners, clamps, and flange connections with penetrating oil
5. Visually inspect exhaust routing and identify resonator location between catalytic converters and muffler

Procedure

1. 1

   Support exhaust system
   Position a floor jack with a block of wood under the muffler assembly to support the weight of the exhaust system aft of the resonator. Raise jack until it just contacts the muffler without lifting the vehicle.
2. 2

   Disconnect rear exhaust hanger
   Locate the rubber exhaust hanger between the resonator and muffler. Use a pry bar or exhaust hanger tool to carefully pry the hanger off its mounting bracket. Work the rubber isolator free from the metal hook on the exhaust pipe.
3. 3

   Disconnect forward exhaust hanger
   Locate the rubber exhaust hanger forward of the resonator. Use the same technique to separate the hanger from its mounting bracket. Allow the exhaust system to lower slightly onto the support jack.
4. 4

   Remove rear flange connection
   Locate the flange connection between the resonator outlet and the muffler inlet pipe. Remove the two flange bolts using a 15mm socket. Separate the flanges and remove the old gasket. If the connection uses a band clamp instead of a flange, loosen the clamp nut and slide the clamp off the joint.
   Torque spec

   Flange Bolts45 Nm (33 lb-ft)

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

   Remove forward flange connection
   Locate the flange connection between the catalytic converter outlet and the resonator inlet. Remove the two flange bolts using a 15mm socket. Support the resonator by hand as you remove the final bolt. Separate the flanges and remove the old gasket.
   ⚠Support the resonator assembly as you remove the final bolt to prevent it from falling and causing injury or damage.
   Torque spec

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

   Remove resonator assembly
   Carefully lower the resonator assembly from the vehicle, maneuvering it around the frame rails and suspension components. Inspect the rubber hangers for tears, cracks, or excessive wear and replace if necessary.
7. 7

   Clean flange surfaces
   Use a wire brush to thoroughly clean the mating surfaces on both the catalytic converter outlet flange and the muffler inlet flange. Remove all old gasket material, rust, and debris to ensure a proper seal with the new gaskets.
8. 8

   Install new resonator
   Position a new exhaust gasket on the catalytic converter outlet flange. Lift the new resonator into position, aligning the inlet flange with the catalytic converter. Insert both flange bolts finger-tight but do not torque yet.
9. 9

   Connect rear flange
   Position a new exhaust gasket on the resonator outlet flange. Align the muffler inlet pipe with the resonator outlet flange. Insert both flange bolts (or position band clamp if equipped) finger-tight. Ensure the entire exhaust system is properly aligned before tightening.
10. 10

    Reinstall exhaust hangers
    Reattach both rubber exhaust hangers to their mounting brackets, ensuring the exhaust system hangs at the correct height and alignment. Use a pry bar if necessary to stretch the rubber isolators onto the hooks. The exhaust should hang without binding or contacting the frame or body.
11. 11

    Torque all fasteners
    Starting with the forward flange connection, torque the flange bolts to specification using a torque wrench. Then torque the rear flange bolts (or exhaust clamp if equipped) to specification. Verify all connections are secure and properly sealed.
    Torque spec

    Flange Bolts45 Nm (33 lb-ft)

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

    Remove support and lower vehicle
    Remove the floor jack from under the muffler. Perform a final visual inspection of all connections, ensuring no tools or parts are left in the work area. Lower the vehicle from the jack stands.

Reassembly

1. Ensure all exhaust hangers are properly seated and supporting the system without stress
2. Verify adequate clearance between exhaust components and frame, body, fuel lines, and brake lines throughout the entire length
3. Check that flange connections are flush and gaskets are properly seated

Verification

• Start the engine and allow it to idle while listening for exhaust leaks at both flange connections
• Check for visible exhaust smoke or soot escaping from connections
• Rev the engine to 2000-2500 RPM and verify no abnormal exhaust noise or rattles
• Perform a test drive and verify normal exhaust tone with no leaks, rattles, or contact noise
• After test drive, re-inspect all connections while the exhaust is warm to verify no leaks have developed

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