How to Install Borla Touring Cat-Back Exhaust - Split Rear Exit (01-03 4.6L) on your Ford F-150

By installing your Borla Performance Exhaust System, you indicate that you have read this document and you agree with the terms stated below. 

It is the responsibility of the purchaser to follow all installation instruction guidelines and safety procedures supplied with your Borla Performance Exhaust System.

Borla Performance Industries assumes no responsibility for damages occurring from misuse, abuse, improper installation, improper operation, lack of responsible care, or all previously stated reasons resulting from incompatibility with other manufacturer’s products and/or systems.

Included with your Borla Performance Exhaust System is a warranty card. Please read it carefully before you begin any work on your vehicle. If you should have any questions regarding our warranty policy, installation, or any other matter pertaining to your new Borla Performance Exhaust System, please give us a call at the number provided on the warranty card.

1. Front pipe
2. Muffler assembly
3. Left over axle pipe
4. Right over axle pipe
5. Left tail pipe assembly
6. Right tail pipe assembly
7. 2.5” Accuseal™ clamp (qty 2)
8. 2.25” Accuseal™ clamp (qty 4)
9. Rubber Bracket (qty 2)
10. Frame rail hanger (qty 2)
11. Bolt (qty 2)
12. Flat washer (qty 4)
13. Lock washer (qty 2)
14. Hex nut (qty 2)

1. Muffler assembly
2. Right over axle pipe
3. Left over axle pipe
4. Right tail pipe assembly
5. Left tail pipe assembly
6. Frame rail hanger (qty 2)
7. Rubber bracket (qty 2)
8. 2.25” Accuseal™ clamp (qty 4)
9. 2.5” Accuseal™ clamp (qty 2)
10. Front pipe
11. Bolt (qty 2)
12. Flat washer (qty 4)
13. Lock washer (qty 2)
14. Hex nut (qty 2)

Caution!!! Never work on a hot exhaust system. Serious injury in the form of burns can result If the vehicle has been in use and the exhaust system is hot, allow vehicle to cool for at least 1 hour. Always wear eye protection when working under any vehicle.  

Note: It is our recommendation that you use a hoist or hydraulic lift to facilitate the installation of your new Borla Performance Cat-Back™ Exhaust System.  

Taking all under car safety precautions, lift the vehicle using a hoist or hydraulic lift. Once this has been done, you may begin the removal of your old exhaust system from your vehicle.  

Note: Before removing the original exhaust system from your vehicle, please compare the parts you have received with the bill of materials provided on the previous pages to assure that you have all the parts necessary for the installation of your new Borla Performance Cat-Back™ Exhaust System. 

Original Exhaust System Removal

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 lubricate the threads before attempting to disassemble. 

1. Loosen the clamp shown in figure 1 in front of muffler assembly.
2. Lubricate all hangers and rubber brackets.
3. Using a muffler stand or an additional person to hold the exhaust system up in place, remove all hangers from the rubber brackets.
4. Finally, remove the old exhaust system shown in figure 2 from your vehicle.

Warning: Use extreme caution during installation. Torque all fasteners according to manufacturer’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. If any welding is performed, protect vehicle brake, fuel, vacuum or similar lines. Always check for any damage after welding has been done. Also check inside vehicle for damage to such items as carpet, inner liner, etc. Always have a class C fire extinguisher and a bucket of water available during any welding process. 

1. To avoid any contact with the exhaust system, tie together the brake lines and differential vent line as shown in figure 3.  

2. Place a clamp over the expanded end of front pipe and place into position. DO NOT tighten the clamp. DO NOT tighten the clamp.  

3. Place a clamp over the expanded end of muffler assembly and place into position sliding the inlet of the muffler over the front pipe.  

4. Place a clamp over the expanded end of both left and right over axle pipes shown in figure 5 and place them into position sliding them over the outlets of the muffler. Install the hangers into the rubber brackets. DO NOT tighten the clamps.  

5. Using the supplied hardware, install both left and right frame rail hangers into position on the outside of both left and right frame rails next to the rear leaf spring shackles. Install rubber brackets on both hangers.  

6. Place a clamp over the expanded end of both left and right tail pipe assemblies and place into position sliding them over the over axle pipes. Install hangers into the rubber brackets.  

7. Check your exhaust system for proper clearance under the vehicle and also for tip alignment.  

8. Once position has been determined to be correct, tighten the Accuseal™ clamps to 32-35 ft. lbs working from the rear of the vehicle to the front.  

9. Before starting your vehicle, make sure to check all wires, hoses, brake lines, body parts and tires for safe clearance from the exhaust system.  

10. Start vehicle and check for any leaks. If any leaks are found, determine cause (such as loose or incorrectly positioned clamp) and repair as necessary.  

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. 

Congratulations!!! You have completed the installation of the world famous Borla Performance Stainless Steel Exhaust System.