I took my 2018 in as I heard more noise than usual and saw exhaust coming out before the muffler. I have the 3.5L. Was at the dealer anyway and was told that my flex pipe on the rear muffler is broke

Ford is out of stock on the exhaust system and wanted $800. I have a big credit at AmericanTruck.com and would like a quieter exhaust. Any suggestions? Tia

 

bump.

Has anyone just swapped out a new flex pipe? Ford is telling me that i have to replace the whole exhaust system for one piece which seems nuts.

 

LOL!!!

Just get it welded up!

 

Ford doesn't offer it as a separate part, but you can absolutely have a new flex pipe welded in by an exhaust shop. Just keep in mind that many exhaust shops and auto repair shops in general only stock aluminized steel exhaust components, aluminized steel typically only lasts 2-3 years in the rust belt. I would recommend finding a shop that uses 304 or 409 stainless steel to get a reasonable service life out of the exhaust.

Aftermarket exhausts are almost always louder, even the factory replacement exhausts tend to be louder than stock. The fitment and material quality from companies like Walker leaves a lot to be desired and living in IL, I wouldn't expect a cheap stock replacement from Walker to last very long.

 

IIRC, Borla sells them, 304 stainless. And if they don't, there are plenty of places to get them, 409 stainless is OEM I think?

 

Thank you guys. Anyone know the diameter of the stock 3.5L exhaust? I am coming up with 2.5" adn 3" on searches and I'll just order one up and bring it to my local shop.

 

It can vary based on where you take the measurement since the pipe isn't a uniform diameter across its entire length. I'm also fairly certain that there has been some minor size variance over the years and between different engine options. Your best bet would be to take a quick measurement on your own truck; I would guess that 2.5" will probably be the correct diameter, but I'm not sure how long the factory flex pipe is.

 

Bumping this back to the top, as I have this problem.

Also being of DIY nature, though cannot weld, what fixes have been done? Rest of my exhaust is in great shape, not wanting to dump.

Also a 2018 3.5 EB 4-Door cab, 5.5' bed

 

that section should be 2.5.

 

Flex pipe is known to develop holes, snap at muffler interface. The only real fix is to replace with unit, sold as a muffler with the flex as a 1 piece. Welding another flex pipe into the exhaust will give you some more time with the same exhaust, and then it will eventually break again. JB weld sells kits that will cover a hole for about 100 miles and then it too will blow out.
I replaced with a FullRace catback. Increases diameter airflow, not too loud. The downside without a flex pipe is increased movement at manifold, and with Ford's idiotic ideas of decreasing bolt numbers and cheap metals, the manifold can warp or twist creating a small gap and noisy startup. If you live in the rust belt get some good steel...