Quick Answer: 2020–2023 Ford 6.7 5-Inch Muffler Exhaust Install
Install the 2020–2023 Ford 6.7L 5-inch muffler system by setting the front pipe and the rear assembly first. Hang the over-axle pipe and tailpipe, fit the muffler to the front of that rear assembly, then measure back to the intermediate pipe. The center extension must cover that gap plus the insertion at both slip joints.
Before you start: The muffler position sets the rear end of your extension measurement. Follow the 5-inch muffler layout below, and check the extension identity and clamp specification before cutting or tightening: 2020–2023 Ford 6.7L 5-Inch Muffler Exhaust Installation PDF.
Why The Extension Must Wait Until The Muffler Is In Place
An extension cut to the open gap can end up too short once both joints slide together. On this kit, the installed muffler and mid-pipe set the measuring points.
Plan the job around those points, not around a pipe layout on the floor. Keep the front and rear supported and adjustable until you have checked the full route.
U.S. emissions rules prohibit tampering with certified controls. A race-use label alone does not establish an exemption.
Match The 5-Inch Muffler System
| Vehicle or layout check | What applies here |
|---|---|
| Truck covered | 2020–2023 Ford 6.7L Powerstroke. |
| Replacement route | 5-inch downpipe-back with muffler; original downpipe retained. |
| Rear reference | Hang the over-axle pipe and tailpipe, then fit the muffler at their front. |
| Center length | Measure between the supported intermediate outlet and installed muffler inlet. |
| Other structures | Short two-piece replacements and Cab & Chassis routes have different length and mounting checks. |
Before You Remove Anything: This guide covers the 2020–2023 Ford 6.7L Powerstroke 5-inch downpipe-back route with a muffler. Confirm the front flange, wheelbase and pickup rear layout. A Cab & Chassis route, a short two-piece DPF pipe or a straight center section needs different length and mounting checks.
The Muffler-System Parts And Measuring Section
| Component name | Illustrated manual reference | How to identify or fit it |
|---|---|---|
| Front flange pipe | 62001 | Connects to the retained downpipe. |
| Intermediate pipe with hanger | 61152NB | Seat the stock rubber isolator before measuring. |
| 5-inch center extension | 9520 in the packing layout | The step text says 9420; identify the actual section by diameter and matching ends. |
| Muffler | 7189 | Locate at the front of the supported over-axle assembly. |
| Over-axle pipe / tailpipe | 62056 / 62057 | Set the rear hangers and outlet before sizing the extension. |
Use the shapes, pipe ends and welded supports in this drawing to match the components listed above.
Plan The Heavy Removal And Extension Measurement
| Tool Or Equipment | What You Need It For |
|---|---|
| Stock removal | At least two people and stands to support the heavy sections. |
| Extension measurement | Tape measure, marker and suitable pipe-cutting tools after the extension is identified. |
| Flanges and clamps | Correct sockets and a torque wrench. Obtain a complete torque value and unit for the supplied clamps. |
Start with a cold exhaust. Support the truck by the approved method and support each heavy pipe before release. Never work under a jack alone.
Phase 1: Remove The Heavy Stock Route With A Helper
Installer Tip: Put the muffler and rear pipes in their installed positions before measuring. The open gap does not include the pipe hidden inside both slip joints.
Step 1: Label The Stock Wiring
Locate and label the exhaust sensor and wire connections. Release them with the correct truck service method. Keep the leads out of the path of the heavy stock sections.
Step 2: Separate The Rear Section
Support the axle and tailpipe route. Remove the rear-most flange bolts. Keep the loose section controlled while you move to the front joint.
Step 3: Remove The Heavy Front Assembly
The PDF calls for at least two people. Support the assembly before removing the two downpipe-connection bolts. Do not let the last bolt carry the whole load.
Phase 2: Place The Front, Rear And Muffler References
Step 4: Fit The Front Flange And Intermediate Pipes
Fit the front flange pipe to the retained downpipe using the matching supplied bolts. Leave it adjustable. Add the intermediate pipe, seat its hanger in the stock rubber isolator and support the free end on a stand.
Step 5: Place The Axle Pipe And Tailpipe
Feed the axle pipe over the rear end and seat its hangers. Fit the tailpipe to the rear hanger and axle pipe. Leave room to adjust the exit position.
Step 6: Set The Muffler Before Measuring
Hang the axle pipe and tailpipe first, then fit the muffler at the front of the axle pipe. Follow any flow arrow on the actual muffler. With the intermediate hanger seated, measure the clear gap between the intermediate outlet and muffler inlet. For a center extension with two slip joints, add the front insertion and rear insertion once each. Do not add them again if the measurement already includes those lengths.
Mark, Cut and Recheck the Muffler-to-Mid-Pipe Extension
Trial-fit the marked length before cutting. Shorten only the permitted plain end of the matching 5-inch extension. Keep its expanded end and any welded support, then deburr inside and outside.
Refit the extension and confirm the insertion marks at both ends. If the muffler has to move or a hanger must stretch to close the gap, restore the supported positions and remeasure before tightening.
Phase 3: Align And Complete The Fastening Pass
Step 7: Align The Whole Route
Check the muffler, rear exit and rubber mounts together. Check the nearby lines, wires and body. The parts should sit right without a clamp pulling them into line.
Step 8: Tighten With A Confirmed Spec
Once the route is aligned, tighten the two front bolts to the verified specification for that hardware, then work rearward. The source’s “45–50 lbs” lacks a complete torque unit; it is not a verified ft-lb instruction. Use the specification for the actual identified clamp and recheck after the heat cycles its maker specifies.
Final Check Before The Front-To-Rear Tightening Pass
- Rear reference: Over-axle pipe, tailpipe and muffler supported in their installed positions.
- Extension: The actual 5-inch section fits both sockets and retains its marked insertion at each end.
- Alignment: Muffler and rear outlet clear the truck without a clamp pulling a pipe into line.
- Fastening: Use the identified hardware specification; incomplete torque units are not treated as an ft-lb value.
Before use, have the joints checked for leaks with the proper shop method. Do not run the engine in a closed space. If there is a new rattle, soot trace or loose support, let the exhaust cool and correct the cause. Follow the supplied hardware maker’s heat-cycle recheck instructions.
Troubleshoot Extension Reach And Clamp Specifications
| What you find | What to check before changing parts |
|---|---|
| Extension is too short after cutting | Check whether both joint insertions were included. An end-face gap alone is not the finished length of a two-ended slip section. |
| Muffler touches a crossmember | Recheck center length and rear-pipe rotation with the clamps loose. Do not raise it by stretching the rubber mounts. |
| Front flange leaks after tightening | Support the intermediate pipe, release tension and reseat the front faces. Check the sealing parts and hardware before tightening again. |
For a 5-inch route with a muffler, use Dp-Back w/Muffler / 5". The shorter DPF Race options do not include the same full rear route. The link selects the muffler-equipped downpipe-back option. View Dp-Back w/Muffler / 5"
[[product-recommend:1]]Before Use: Calibration And Leak Checks
Arrange the compatible calibration and any device or service your exact package needs before use. Exhaust fitting does not include ECU programming. Diagnose warning lights, reduced power or leaks before operating the truck.
Conclusion
The muffler sets the rear measuring point. With the front and rear assemblies supported, size the center extension for the gap and real engagement. Align, tighten to the identified hardware specifications and recheck after the required heat cycles.
For related parts on the same platform, browse 2020+ 6.7L Powerstroke parts.
Choose The 5-Inch Muffler Route
Use the vehicle and option table above to match your build. The collection includes other pipe sizes and layouts, so keep the exact option name with your parts list.
References
- SPEtuner: "ES08692S5.0 illustrated installation instructions." Available from SPEtuner installation PDF.
- U.S. Environmental Protection Agency: "EPA Fact Sheet re Aftermarket Defeat Devices and Tampering." Available from U.S. Environmental Protection Agency.
- Cover photo: "Bull-Doser: "2020-2022 Ford F-250 Super Duty Crew Cab Power Stroke 4x4.jpg — Public domain. Layout added; vehicle photo retained." Available from Cover photo: Bull-Doser.
FAQ
Q: Does This Guide Cover A 2024 Ford Truck?
A: The PDF lists 2020–2023. It does not prove later-year fitment.
Q: Why Does The Muffler Go In Before Measuring?
A: Its inlet sets the rear end of the extension gap. Measure only after the muffler and rear route are supported in place.
Q: Should I Torque The Clamps To 45–50 Ft-Lb?
A: The copied instruction does not give a complete torque unit, so that is not a verified ft-lb specification. Use the specification for the actual identified clamp and fastener.
Q: Can I Measure The Extension Before Hanging The Muffler?
A: No. The guide places the muffler at the front of the axle pipe first. Measure from its front connection to the installed mid-pipe and include both end engagements.
Q: Can One Person Remove The Stock Assembly?
A: The PDF calls for at least two people because the assembly is heavy.
Q: When Should I Recheck The Clamps?
A: The PDF says after a few hot/cold cycles. Use the confirmed clamp spec for that check.
Lars
Diesel Performance Engineer | 15+ Years Experience
"Empower Your Beast: Run Cooler, Pull Harder, Last Longer."
