How to Install Corsa 3 in. Sport Cat-Back Exhaust w/ Twin Polished Tips - Single Side Exit on your F-150

CORSA recommends that the installation of this system be performed by a qualified service center or professional muffler installer who has the necessary equipment, tools and experienced personnel. However, if you decide to perform this install, the use of a hoist and an additional person will be required. 

CAUTION: Never work on a hot exhaust system. Allow time for the vehicle to cool. Always wear eye protection when working under a vehicle. 

1. Loosen the clamp connection located after the stock resonator using a 15mm deep socket and ratchet. The stock clamp is welded to the resonator assembly and cannot be removed or rotated. (Fig A)  

2. Loosen the two 13mm bolts at the resonator flange connection. Do not completely remove these bolts. (Fig B) Place a jack stand or similar device under the outlet end of the resonator for support.  

3. Rotate the stock resonator clockwise until the retaining boss on the stock cat-back exhaust is aligned with the slot on the resonator. (Fig C)  

4. For the 5.0L engine only - Use the grommet pullers to remove only the front muffler hanger from its grommet. (Fig D)  

Note: The use of a soapy water solution may aid in the removal of hangers.  

5. Slide the entire stock system rearward to free all remaining hangers from their grommets. Also, make sure that the front muffler pipe cleanly separates from the resonator pipe. Use caution at this step as the weight of the exhaust system will no longer be supported by the grommets. (Fig E, F, & G)  

Note: The use of a soapy water solution may aid in the removal of hangers.  

6. Once all hangers are removed from their grommets, remove the entire system from the vehicle by lowering it down as you slide it forward and allowing the tailpipe to travel over the rear axle. (Fig H)  

7. The stock exhaust should now be clear of the vehicle. (Fig I for the 5.0L)(Fig J for the 2.7L/3.5L) 

NOTE: Apply the anti-seize lubricant (supplied) to the threads ONLY of all the clamps and flange bolts. Failure to follow this procedure can cause nuts to seize on clamps and potentially destroy threads. After applying anti-seize lubricant, be sure to thoroughly clean your hands, as lubricant will tarnish stainless steel. All clamps should be tightened using a properly calibrated Torque Wrench. Using an air impact gun will damage the clamp and reduce its ability to effectively seal the joint. It may also cause the joint to separate, thereby causing damage to your exhaust system and to your vehicle.  

NOTE: Align all clamps so that the center of the clamp bolt is 90 degrees from the notch in the pipe. (See Fig. CLAMP) 

1. Remove all exhaust components from the shipping carton, including the 2 supplied 3” clamps.  

2. Locate the CORSA Performance muffler and align the inlet to the stock resonator outlet along with the front muffler hangers to their corresponding grommets. Insert the muffler inlet into the resonator outlet along with the rear hangers. (5.0L - Fig K) (2.7L & 3.5L Fig L)  

Note: The use of a soap and water solution may aid in the installation of the hanger grommets.  

3. Rotate the stock resonator so that the drain hole, located on rear endcap, is towards the ground. Once the drain hole is in proper position, snug the factory clamp connection using a 15mm socket and ratchet. (Fig M)  

4. Locate a 3” Torca clamp and install it over the expanded end of the tailpipe. (Fig N) Slide the tailpipe over the rear axle and position the tailpipe hangers in-line with their corresponding hanger grommet assemblies. Once the tailpipe is positioned slide the tailpipe assembly forward to install the hangers. (Fig O & P)  

Note: Removing the rear tailpipe grommet assembly from the vehicle and installing it on the rear tailpipe hanger beforehand may simplify the installation, but is not required if the tailpipe is positioned correctly.  

5. Insert the muffler outlet pipe into tailpipe inlet, properly position the clamp and snug it using a 15mm deep socket and ratchet. (Fig Q & R)  

6. Locate the tip assembly and 3” Torca clamp. Properly align the clamp onto tip inlet and install tip onto tailpipe outlet. (Fig S & T) Snug the clamp using a 15mm deep socket and ratchet. (Fig U) 

7. Check the alignment of tip assembly to the rear quarter panel. Ideally, tip edge should be flush with fender and rotation of tips should be parallel with bottom edge of fender. Adjust tip rotation and overlap as necessary. (Fig V)  

8. Visually inspect the exhaust system position, tip alignment, clamp orientation and position, and exhaust pipe clearance. Make any necessary adjustments at the slip joints.  

9. Fully tighten the 13mm bolts at the flange connection and torque to factory specs. Next, tighten the factory clamp at the resonator/muffler connection to 45 ft-lbs.  

10. Starting at the front of the vehicle, tighten the nuts on the two supplied clamps. Torque the clamps to 45 ft-lbs.  

11. It is STRONGLY SUGGESTED that all clamps be checked and re-tightened (if necessary) to the recommended torque after initial road testing of the vehicle, as thermal cycling has occurred on the system. Please wait until the system has fully cooled to perform this step.  

NOTE: During cold weather start-ups, you may experience an exhaust sound that is deeper and louder in tone than usual. This is temporary and will diminish to normal levels once your engine has reached its normal operating temperature.  

NOTE: Immediately following the installation of your exhaust system, you may experience a trace of smoke after initial start-up. DO NOT be alarmed. The smoke is caused by the burning of a small amount of forming oil residue used in the manufacturing process.