FLOWMASTER 718154 2021-2023 Ford Bronco Sport OEM Exhaust Installation Guide

Installation Instructions
718154
2021-2023 Ford Bronco Sport
1.5 and 2.0L Engine

718154 2021-2023 Ford Bronco Sport OEM Exhaust

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: 2021- 2023
Make: Ford
Model: Bronco Sport
Engine: 1.5L or 2.0L Eco Boost

Note: Requires cutting the factory exhaust

BEFORE 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.

Cutting the factory exhaust pipe just before the muffler as shown in Fig.1 and Fig.2

• This process is the same for 1.5L or 2.0L Engines

  1. Measure 2.5” from the factory muffler body (A) and make a reference mark (B) on the exhaust pipe (C) Fig.1.
  2. Use painter’s tape at the witness mark to make a straight edge to follow when cutting. Fig.2
  3. Cut exhaust pipe at the witness mark, following the tape edge as you go. Fig.2
  4. Deburr the inside and outside of the tubing. Removing the OEM Exhaust: Continued
  5. Support the OEM muffler assembly with jack stands.
  6. Remove the M10 nut securing the wire harness to the passenger side exhaust hanger stud and remove the harness clip from the stud.
  7. Remove the M10 Studs (X1) from each exhaust hanger assembly.
  8. Remove the OEM Muffler assembly from the vehicle.

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. Remove the hanger assemblies from the OEM muffler and transfer them to the Flow FX Axle-Back exhaust hanger rods (E). Fig.5
2. Install the FlowFX muffler assembly into the vehicle (F) and install the M10 studs (x1 each side) into the hanger rod assembly’s and tighten (G). Fig.5
3. Install the 2.5” band clamp (6) (largest of the three clamps provided) over the muffler inlet pipe (H). Bolt on the right-side nut facing the ground. Fig .5

NOTE: This kit is designed to accommodate the 1.5L and 2.0L exhaust systems. You must use the correct adapter pipe and band clamps for the exhaust system your vehicle is equipped with. Follow the steps outlined below for your application. Use the parts list and diagram to identify the parts required.

LITER ENGINE INSTALLATION

• Adapter Pipe “A” PN: TB943M (2) This will be the adapter pipe supplied with No step down
• Band Clamp PN: MC248BS (63mm) (5)
• Modification to the Heat shield (2.0L ONLY)

1. The lip, on the heat shield just before the muffler will need to be rolled back on 2.0L applications. -This can be done on the vehicle
   • Use a large flat blade screwdriver to lift the edge of the heat shield to a 45 degree angle.
   •  Use a small hammer to work the lip of the heat shield back to the weld and then flatten the heat shield edge back over itself. Fig. 6, 7

2. Install adapter pipe “A” (2) (no step down) into the muffler inlet pipe (H). Fig.8
   Important: Be sure the Z-Notch is out.

3. Install the provided 63mm band clamp (5) over the OEM exhaust pipe (C) with the bolt to the right and the nut facing down. Fig.8

4. Align the muffler adapter pipe (2) to the OEM Exhaust pipe and slide the adapter pipe down and over the OEM exhaust pipe and into the band clamp (5). Slide the adapter down until it touches the rolled heatshield edge. Fig.8

5. Install the band clamp over the Z-Notched end of the adapter pipe and tighten as close  to the end of the pipe as possible. Fig. 8

6. Slide the Muffler down on to the adapter pipe as far as possible leaving approximately a 1/8” gap between the clamps. Tighten the 2.5” band clamp to allow for adjustment.

7. Make the final adjustments to the muffler aligning the tips to the cut outs in the rear valance.

8. Tighten the clamps and install the push nuts onto the hanger rods at the hanger isolators to keep the tips centered in the vallance.

NOTE: There should be a minimum of ¾”inch between the tip and the rear vallance. The soft plastic valance is easily trimmed if needed.

1.5 LITER ENGINE INSTALLATION

• Adapter Pipe “B” PN: TB944M (3) This will be the adapter pipe supplied with Step Down
• Band Clamp PN: MC217BS (2.17 in), (7) (smallest of the three clamps provided clamps provided)
• Modification to the Heat shield – Not Required

1. Install adapter pipe “B” (3) (with Step Down) into the muffler inlet pipe (H). Fig.9 Important: Be sure the Z-Notch and reduced end are out.

2. Install the provided 2.17in band clamp (7) over the OEM exhaust pipe (C) with the bolt to the right and the nut facing down. Fig.9

3. Align the muffler adapter pipe (3) to the OEM Exhaust pipe and slide the adapter pipe down and over the OEM exhaust pipe (C).

4. Slide the adapter down until the step-down edge is approximately ¼” out of the muffler.
   Tighten the 2.5” band clamp on the muffler inlet. Fig.9

5. Slide the 2.17in Band clamp (7) over the adapter and align the clamp to the edge of the adapter (3). Tighten the 2.17in clamp with the adapter approximately ½” from the bend. Fig.9 

6. Tighten the clamps and install the push nuts onto the hanger rods at the hanger isolators to keep the tips centered in the valance.

NOTE: There should be a minimum of ¾”inch between the tip and the rear valance. The soft plastic valance is easily trimmed if needed.

Enjoy Your Flowmaster Exhaust!

718154
www.flowmastermufflers.com
1-866-464-6553

References

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

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