FLOWMASTER 818153 Front Wheel Drive or All Wheel Drive Instruction Manual

Installation Instructions
818153
2022-2023 Ford Maverick
2.0L Engine
Front Wheel Drive or All Wheel Drive

818153 Front Wheel Drive or All Wheel Drive

Installation requires Cutting the OEM exhaust and moderate mechanical skill. If this job is beyond your abilities, seek the services of a qualified technician.
If you do not understand any part of these instructions, please call Flowmaster Technical Support at 866-464-6553 for assistance.
Apply penetrating oil generously to clamps, fasteners, pipes, and hanger rods for ease of disassembly.

REVIEW THE INSTRUCTIONS & VERIFY THE KIT CONTENTS

Take a moment to read and understand these instructions before installing your Flowmaster exhaust kit.

Use the parts drawing and list to identify components and verify your kit’s contents. In the unlikely event that any parts are missing, please contact Flowmaster Technical Support for replacements.

Vehicle Compatibility
Model Year: 2022-2023
Make: Ford Maverick
Engine: 2.0L Eco Boost

• Front Wheel Drive and All Wheel Drive models
• Side exit and Rear exit tailpipe configurations are included.

EFORE STARTING:

Raise the vehicle to a minimum of eighteen inches. A floor hoist is ideal. If no hoist is available, we strongly urge the use of axle stands as a safety measure. Please read and understand these instructions and disclaimer in their entirety before attempting installation.

CAUTION! WORK ONLY ON A LEVEL SURFACE. USE JACKS /JACK STANDS OF SUFFICIENT CAPACITY TO LIFT AND SUPPORT YOUR VEHICLE. NEVER WORK UNDER A VEHICLE SUPPORTED BY A FLOOR OR BUMPER JACK.

Removing the OEM Exhaust:

NOTE: Cutting the factory exhaust is necessary. Please read and follow all instructions before attempting to install this exhaust system.

1. Apply penetrating oil to each rubber hanger on the exhaust.

2. Make a witness line across the clamp connection just before the catalytic converter (see Fig. 1). Start the witness line on the pipe before the clamp and extend over the clamp onto the pipe on the opposite side of the clamp.
   IMPORTANT: This will provide an alignment reference to reinstall the catalytic converter after the cut is made to the exhaust pipe as outlined in Step 3 / Fig. 2 Optional Procedure.NOTE: The Factory exhaust is one large, welded assembly and is difficult to manage when the hangers are removed. Cutting the exhaust after the center muffler will make removal less difficult as two pieces.

3. Mark the OEM exhaust where it will be cut just after the catalytic converter. See Fig. 2.
   NOTE: Using a piece of masking tape around the pipe will provide a reference line when making the cut.
   Optional Procedure: Removing the exhaust before cutting at the location outlined in Step 3 & 6 is not required, but is recommended to avoid damaging the heat shields. See Steps 7, 8, & 9.

4. Support the Exhaust assembly before making cuts, removing any rubber hangers or the clamp at the catalytic converter.

5. Using a reciprocating saw or cut off wheel, cut the Catalytic Converter from the exhaust system.
   Use the inside tape edge as a guide to make a straight cut (Fig. 3).

6. Remove the rubber exhaust hangers from the pipes and muffler hanger. Then, remove the entire exhaust assembly.
   CAUTION: The exhaust assembly is heavy and awkward. Please take caution when attempting to remove the assembly from the vehicle. Cutting the exhaust at the center muffler and removing it as two pieces will make handling the parts less difficult.
   Optional procedure:
   If you have chosen to cut the exhaust at the catalytic converter as outlined in Steps 3 & 5 after the system has been removed from the car, please follow Steps 7, 8, & 9 below.

7. Remove the clamp from the catalytic converter.
   NOTE: Bending the locking tabs is required to allow the pipes to separate from the clamp. Be sure to only bend them enough to remove the clamp.

8. Using a reciprocating saw or cut off wheel, cut the Catalytic Converter from the exhaust system as outlined in Steps 3 & 5. Use the inside tape edge as a guide to make a straight cut (Fig. 3).

9. Reinstall the catalytic converter and clamp, align the witness marks made in step two Fig. 1 to ensure proper alignment. Tighten the clamp and support the catalytic converter to avoid damaging the flex section.

INSTALL YOUR FLOWMASTER EXHAUST SYSTEM

Before installing clamps in the following steps, remove their nuts, apply anti-seize compound to the bolt threads, and re-install the nuts.

1. Install the supplied 63mm band clamp (6) into the reduced end of the muffler inlet pipe (1) with the bolt to the inside and nut facing down (Fig. 4).
2. Install the muffler inlet pipe (1) reduced end on to the catalytic converter (A). Rotate the inlet pipe level with the outlet towards passenger’s side of the vehicle. Snug the clamp just enough to hold the pipe in place, but allow for adjustment later (Fig. 5).
3. Install a supplied 3” band clamp (9) onto the expanded end of the muffler assembly (2) with the bolt to the inside and nut facing down.
4. Install the expanded end of muffler assembly (2) onto the inlet pipe (1). Install the blue rubber hanger rod isolator (B) and tighten the clamp enough to hold the pipe, but allow for adjustment.
5. Install the clamp hanger (7) for Front Wheel Drive vehicle installation or clamp hanger (8) for All Wheel Drive applications (Fig. 7). Install with the bolt to the inside and nut facing down. Align the hanger rod with the factory muffler hanger and install the orange hanger rod isolator (C). Tighten the clamp enough to hold the pipe, but allow for adjustment.
6. Install a 3” band clamp on to the expanded end of the tailpipe to be installed.
7. Install the side exit tailpipe (3) Shown (Fig. 6) or the rear exit tailpipe (4) See Fig. 7. Install the blue rubber isolator on to the hanger rods at the rear of the car (D).
8. Adjust the system for best component clearance and overall fitment. Start at the front of the system and work towards the rear of the vehicle, tightening the clamps as you go.
9. Install tip, align as desired, and tighten the clamp.
10. Install the hanger rod retainers.

Enjoy Your Flowmaster Exhaust!
818153 Date: 3/23/23
www.flowmastermufflers.com
1-866-464-6553 Page 8 of 8

References

• Flowmaster - Mufflers & Exhaust | Holley.com
• Flowmaster - Mufflers & Exhaust | Holley.com

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