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

Warnings

Tools required

Parts

• Tail pipe assembly × 1 — Use OEM specification or equivalent
• Exhaust flange gasket × 1 — Use OEM specification
• Rubber exhaust hangers (if damaged) × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground and apply parking brake
2. Place wheel chocks at front wheels
3. Allow exhaust system to cool completely (minimum 2 hours after engine operation)
4. Raise rear of vehicle with floor jack and support securely on jack stands rated for vehicle weight
5. Verify vehicle is stable before working underneath
6. Apply penetrating oil to all exhaust flange bolts and hanger bolts, allow 10-15 minutes to penetrate

Procedure

1. 1

   Inspect exhaust system
   Visually inspect the tail pipe assembly, flanges, hangers, and connections. Identify the connection point between the tail pipe and muffler or mid-pipe. On the 3.5L EcoBoost, the tail pipe connects to the rear muffler outlet with a flanged connection. Note the location of rubber hangers supporting the tail pipe.
2. 2

   Support tail pipe assembly
   Position a floor jack or suitable support under the tail pipe near the muffler connection to support the weight of the tail pipe during removal. Raise just enough to take tension off the hangers but do not lift the vehicle.
   ⚠Ensure support is stable to prevent tail pipe from falling during removal.
3. 3

   Remove exhaust flange bolts
   Locate the exhaust flange connecting the tail pipe to the muffler outlet. Using a 15mm socket, remove the exhaust flange bolts. There are typically 2 bolts securing this connection. If bolts are severely corroded, apply additional penetrating oil and use a six-point socket to prevent rounding.
   ℹ️Keep flange bolts if reusing; inspect threads for damage.
   Torque spec

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

   Separate flange connection
   Gently pry the flange connection apart using a pry bar if necessary. Remove and discard the old exhaust flange gasket. The gasket is compressed and should not be reused.
5. 5

   Release rear exhaust hanger
   Locate the rearmost rubber exhaust hanger supporting the tail pipe. Using a pry bar or exhaust hanger removal tool, carefully push or pry the tail pipe bracket off the rubber hanger. Work slowly to avoid tearing the rubber hanger.
   ⚠Exhaust hangers are under tension and may snap back when released.
6. 6

   Release mid exhaust hanger
   Locate the middle rubber exhaust hanger on the tail pipe assembly. Using the same technique, release the tail pipe bracket from this rubber hanger. Lower the support jack slightly if needed to relieve tension.
7. 7

   Remove tail pipe assembly
   With all hangers released and flange disconnected, carefully lower and remove the tail pipe assembly from the vehicle. Maneuver as needed to clear the rear axle and frame components.
8. 8

   Clean flange surfaces
   Using a wire brush, thoroughly clean the muffler outlet flange surface. Remove all old gasket material, carbon deposits, and corrosion. The surface must be clean and flat for proper sealing.
9. 9

   Inspect exhaust hangers
   Inspect the rubber exhaust hangers for cracks, tears, or excessive wear. Replace any damaged hangers. Check that the hanger mounting points on the frame are secure.
10. 10

    Install new tail pipe assembly
    Position the new tail pipe assembly and align with the exhaust hangers. Install the tail pipe brackets onto the rubber hangers, starting with the rearmost hanger first. Use a pry bar or soapy water to ease installation if needed.
11. 11

    Install new flange gasket
    Place a new exhaust flange gasket between the muffler outlet flange and the tail pipe inlet flange. Ensure the gasket is properly centered and aligned with all bolt holes.
12. 12

    Install and torque flange bolts
    Apply a thin layer of anti-seize compound to the threads of the exhaust flange bolts. Insert both flange bolts and thread them by hand to ensure proper alignment. Using a torque wrench and 15mm socket, tighten the exhaust flange bolts in a crisscross pattern to the specified torque of 45 Nm (33 lb-ft).
    Torque spec

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

    Adjust tail pipe position
    Verify the tail pipe exits cleanly past the rear bumper with adequate clearance. Adjust the position by loosening the flange bolts slightly, repositioning as needed, then re-torquing to specification. Ensure there is at least 25mm clearance from all body panels and suspension components.

Reassembly

1. Ensure all exhaust hangers are fully seated and supporting the tail pipe weight
2. Verify tail pipe tip extends evenly past bumper and is aesthetically aligned
3. Check that no exhaust components contact the frame, fuel lines, or brake lines

Verification

• Remove jack stands and lower vehicle to ground
• Start engine and allow to idle for 2 minutes, listening for exhaust leaks at the flange connection
• Visually inspect flange connection for any signs of exhaust gas escaping
• Rev engine to 2000 RPM and verify no abnormal exhaust noise or leaks
• Take a short test drive and verify tail pipe remains properly positioned with no rattles or vibrations
• After test drive, re-inspect flange connection while engine is warm to confirm seal integrity

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