Installation Guide for FLOWMASTER models including: 818148 Force II Exhaust Kit, 818148, Force II Exhaust Kit, II Exhaust Kit, Exhaust Kit
Installation Instructions 818148 2021-23 FORD F-150 with 2.7L, 3.5L, and 5.0L ENGINE 2- or 4-WHEEL DRIVE, ALL EXCEPT 122" WHEELBASE (REGULAR CAB, 6½' BED) See "Applications" tab on the product web page for specific applications. 12 ITEM PART NO. DESCRIPTION QTY. 10 1 26907S HEAD PIPE 1 2 26277S EXTENSION PIPE 1 3 8530552-Z FORCE II MUFFLER 1 4 86323S LEFT OVER-AXLE PIPE 1 2 5 86327S RIGHT OVER-AXLE PIPE 1 6 86324S LEFT TAILPIPE 1 7 26629S REAR EXIT PIPE 2 8 ST462 TIP, STAINLESS STEEL 2 9 490HA CLAMP HANGER 1 10 MC300BS CLAMP, STAINLESS, 3" 2 11 MC250BS CLAMP, STAINLESS, 2-1/2" 5 12 SF059 FLANGE 1 13 HW103 NUT, 3/8-16 1 14 HW309 LOCK WASHER, 3/8" 1 15 525HA FRAME HANGER 1 16 HW234 BOLT, 3/8-16 × 3-1/2" 1 4 17 HA566 BACKING PLATE 1 18 HA168 HANGER, RUBBER 1 19 HW502 HANGER KEEPER, 7/16" 2 11 20 HW505 CABLE TIE, 15" 1 6 19 15 14 18 11 16 17 13 7 8 20 818148 Rev 01/11/23 www.flowmastermufflers.com Technical Support (866) 464-6553 1 9 10 3 11 (×2) 5 Page 1 of 5 NOTES · Installation requires moderate mechanical skill. If this job is beyond your abilities, seek the services of a qualified technician. · If you do not understand any part of these instructions, please call Flowmaster Technical Support at (866) 464-6553 for assistance. · Use stands to support exhaust system components, both when removing the stock system, and when installing your new kit. · Apply penetrating oil generously to clamps, fasteners, pipes, and hanger rods for ease of disassembly. REVIEW THE INSTRUCTIONS & VERIFY THE KIT CONTENTS Take a moment to read and understand these instructions before installing your Flowmaster Force II exhaust kit. 1. Raise the vehicle to working height on a lift. If you do not have a lift, securely support the vehicle on jack stands. NOTE: If a lift is used, the entire stock exhaust system can be removed, whole, by two persons. But cutting the tailpipe off makes removal easier, especially if the job is performed on jack stands. CUT Use the parts drawing and list to verify your kit's contents. In the unlikely event that any parts are missing, please contact Flowmaster Technical Support for replacements. HANGER 2. Cut the tailpipe off just behind the muffler. Disengage the tailpipe's hanger rod from its rubber isolator, and remove the tailpipe from the vehicle. REMOVE THE FACTORY EXHAUST SYSTEM WARNINGS · AVOID BURNS! Exhaust systems get extremely hot. Allow the vehicle to cool down fully before starting work. · AVOID SERIOUS INJURY OR DEATH BY CRUSHING! Never work under a vehicle that is supported by jacks. 3. Remove and retain the 2 fasteners from the inlet pipe flange. 818148 Rev 01/11/23 www.flowmastermufflers.com Technical Support (866) 464-6553 Page 2 of 5 FRONT ISOLATOR SCREWS REAR ISOLATOR SCREW 4. Remove the screws from the muffler's front and rear isolators. Then remove the assembled inlet pipe, muffler, and isolators from the vehicle. INSTALL YOUR FLOWMASTER EXHAUST SYSTEM CAB BED WB Regular 8' 141" Super 61/2' 145" Super Crew 51/2' 145" Super Crew 61/2' 157" Super 8' 164" HEAD PIPE MOD CUT BACK 4" Not required Not required CUT BACK 6" Not required PARTS REQUIRED Head pipe only Head pipe only Head pipe only Head pipe + extension Head pipe + extension 7. Use this table to determine: A. if your head pipe (1) needs to be modified; and B. if your truck requires the extension pipe (2). 157" WB 141" WB 8. FOR 141" AND 157" WHEELBASE TRUCKS: Cut the head pipe back as specified in Step 7. 5. Remove the isolators from the muffler, then reinstall the rear isolator on the frame. (One front isolator will be installed later.) 12 1 16 15 13 14 17 18 6. On the driver's side frame (between the leaf spring and spare tire), install frame hanger (15) using the 3-1/2" bolt (16) (on outside of frame), and backing plate (17), lock washer (14), and nut (13) (on inside of frame). Lightly snug the fasteners (to allow final adjustment later). Lastly, slide rubber hanger (18) onto the rod. 9. Slip flange (12) over the head pipe (1), then attach the head pipe to the catalytic converter flange using the stock fasteners. Lightly snug the fasteners (to allow final adjustment later). 818148 Rev 01/11/23 www.flowmastermufflers.com Technical Support (866) 464-6553 Page 3 of 5 ISOLATOR 5 11 10. Before installing any clamps, remove their nuts, apply antiseize compound to the bolt threads, and re-install the nuts. NOTE: All pipe-to-pipe slip-fit connections must seat 3" deep. All pipe-to-muffler connections must seat 2" deep. Mark the male ends of each pipe in advance, to ensure proper insertion during assembly. 11. FOR 157" AND 164" WHEELBASE TRUCKS: Slip a 3" clamp (10), and extension pipe (2), onto the head pipe. Verify 3" of insertion, and snug the clamp slightly (to allow final adjustment later). 14. Slip a 2-1/2" clamp (11) over the muffler's right outlet. Move the right over-axle pipe (5) into place, and slide its hanger rod into the isolator. Then slip the end of the pipe into the muffler's outlet, verify 2" of insertion, and snug the clamp slightly. 4 ISOLATOR 11 9 12. Slide clamp hanger (9) over the head (or extension) pipe. Slip a front isolator over the hanger rod, and use the stock screws to attach it to whichever frame location gives the best fit for your truck. Snug the screws and clamp lightly (to allow final adjustment later). 15. Slip a 2-1/2" clamp (11) over the muffler's left outlet. Move the left over-axle pipe (4) into place, slide its hanger rod into the isolator, and slip the end of the pipe into the muffler's outlet. Verify 2" of insertion, then snug the clamp slightly. 19 11 10 6 3 13. Slip a 3" clamp (10) onto the head (or extension) pipe. Slip muffler (3) onto the pipe, support it with a stand, verify 2" of insertion, and snug the clamp slightly. 16. Slip a 2-1/2" clamp (11) over the front of the left tailpipe (6), and move the pipe into place. Slip it onto the left over-axle pipe, slide its hanger rod into the rubber hanger installed at Step 6, and install the two hanger keepers (19). Verify 3" of insertion, and snug the clamp slightly. 818148 Rev 01/11/23 www.flowmastermufflers.com Technical Support (866) 464-6553 Page 4 of 5 8 7 11 17. Slip a 2-1/2" clamp (11) over each rear exit pipe (7), and install each one on its tail pipe. Align each exit pipe as desired, verify 3" of insertion, and snug each clamp slightly. Install a tip (8) on each rear exit pipe. Align each tip as desired, and tighten its clamp. Congratulations, the installation of your Flowmaster Force II performance exhaust system is complete! KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE Flowmaster maintains a highly-trained technical service department to answer your technical questions, provide additional product information and offer various recommendations. 20 FLOWMASTER TECHNICAL SUPPORT: (866) 464-6553 18. Adjust all components to give 1/2" to 3/4" clearance (about a finger's width) around them, and allowing for suspension travel and vibration. (If necessary, relocate the front isolator and clamp hanger, installed at Step 12.) When you are satisfied with the system's clearance and fit, tighten all clamps and hardware. Use cable tie (20) to keep electrical and fluid lines away from exhaust components. RECOMMENDED: Tack weld each slip-fit connection (approx. 1" weld) for added security, then paint each weld with high-temp spray paint to protect against corrosion. 818148 Rev 01/11/23 www.flowmastermufflers.com Technical Support (866) 464-6553 Page 5 of 5Adobe InDesign 18.1 (Windows) Adobe PDF Library 17.0