How to Install Borla Off-Road Downpipe (15-16 3.5L EcoBoost) on your Ford F-150

Note: With a used vehicle, we suggest a penetrating spray lubricant to be applied liberally to all exhaust fasteners and allowing a significant period of time for the chemical to lubri-cate the threads before attempting to disassemble. 

Original Down Pipe System Removal

1. Remove the exhaust cover and retaining hardware for re-installation. (See Fig. 1)  

2. Loosen and remove clamp on L/H pipe behind catalytic converter (See Fig. 2A). Use a metal-cutting-bladed saw, cut the R/H catalytic con-verter close to the weld at the Y-pipe. (See Fig. 2B)  

3. Loosen and remove (2) flange nuts from the R/H catalytic converter and remove from the vehicle. (See Fig. 3) Deburr the outlet side of the R/H converter.  

4. Loosen and remove (2) flange nuts from the L/H catalytic converter and remove from the vehicle, and retaining hardware for reinstallation.  

5. Using a muffler stand or an additional person to support the L/H cross-over pipe assembly, loosen and slide the converter down. Remove the hangers from the rubber isolators and remove the L/H crossover pipe assembly from the vehicle. (See Fig. 4)

WARNING: Use extreme caution during installation. Torque all fasteners according to manufactur-er’s torque values and tightening sequence. DO NOT use air impact tools to tighten fasteners on Borla Performance Exhaust Systems. Use of such tools may result in bent flanges or gasket contact areas leading to exhaust leaks. 

NOTE: When you first start your vehicle after the installation of your new Borla Performance Exhaust System, there may be some smoke and fumes coming from the system. This is a protective oil based coating used in the manufacturing of mandrel bent performance exhaust tubing. This is not a problem and will disappear within a very short period of time after the exhaust has reached normal operating temperatures. 

1. Orient components on floor for your Part Number referencing drawings on pages 2-6.  

2. Using the original hardware install the OE R/H & L/H catalytic converters to vehicle. Place a clamp over the expanded end of the L/H Front Pipe As-sembly and install to L/H catalytic converter outlet. Insert hangers into the rubber isolator. (See Fig. 1)  

3. Place a clamp over the expanded end of the R/H Front Pipe Assembly and install to R/H catalytic converter outlet. (See Fig. 1)  

4. Place clamps over the expanded ends of the X-pipe Assembly and insert the inlet to the L/H and R/H Front Pipe Assemblies. (See Fig. 2) Do not tighten the clamps.  

5. Place a clamp over the expanded end of both Intermediate Pipe Assem-bles and insert the inlet into the outlet of the X-Pipe Assembly. Insert the hangar into the rubber isolator. (See Fig. 3) Do not tighten the clamp.  

6. Place a clamp over the expanded end of the L/H Muffler Assembly and insert the inlet into the L/H Intermediate Pipe. (See Fig. 4) Do not tighten the clamp.  

7. Place a clamp over the expanded end of the R/H Muffler Assembly and insert the inlet into the R/H Intermediate Pipe. Insert the hanger into the rubber isolator. Do not tighten the clamp. (See Fig. 4)  

8. Refer to installation instructions for your Borla True Dual catback ex-haust.  

WARNING: Use extreme caution during installation. Torque all fasteners according to manufactur-er’s torque values and tightening sequence. DO NOT use air impact tools to tighten fasteners on Borla Performance Exhaust Systems. Use of such tools may result in bent flanges or gasket contact areas leading to exhaust leaks. 

NOTE: When you first start your vehicle after the installation of your new Borla Performance Exhaust System, there may be some smoke and fumes coming from the system. This is a protective oil based coating used in the manufacturing of mandrel bent performance exhaust tubing. This is not a problem and will disappear within a very short period of time after the exhaust has reached normal operating temperatures.