I have a ‘94 F-150 and I just noticed that the muffler has holes and the rest of it is in bad condition so I am going to replace it all. The previous owners got aftermarket exhaust and it is all welded on. The Haynes manual can‘t tell me how to do it because the stock exhaust was clamped on. Thanks!
Since you're replacing it, just go ahead and remove it with any means available to you. You shouldn't need to make more than two cuts to remove the exhaust pipe, muffler, and tailpipe. If the brackets / hangers are in okay shape you may want to save them.
hacksaw,sawzall,torch,big hammer
if you plan on keeping the headers start where they are connected and move back. It hard to say how the exhaust is bolted or welded up since it is aftermarket. Is it bolted to the headers? Unbolt it. Is it welded to the headers? Cut it. I would unbolt and make the necessary cuts first, then remove the hangers and the exhaust will just fall down. Dont forget to undo the sensors as you dont want to tear the wires or mess them up if you plan on re-using them. It doesnt matter if you cut or remove the hangers first as long as the exhaust doesnt land on your face when you do either you will be fine. If you are removing it from the headers back I would unbolt it at the headers then remove the hangers and let it fall since there is no reason to disconnect any other part from the exhaust.
