Why Upgrade to a Borla S‑Type Turbo‑Back Exhaust on a 2019 Ford F‑150

Replacing the factory exhaust on your 2019 Ford F‑150 with a Borla S‑Type turbo‑back system is one of the most effective ways to unlock additional horsepower, sharpen throttle response, and give the truck a more aggressive yet refined tone. Unlike a simple cat‑back swap, a turbo‑back exhaust replaces every pipe from the turbocharger outlet to the tailpipe, eliminating factory restrictions and allowing the engine to breathe freely. The result is a noticeable seat‑of‑the‑pants gain in mid‑range torque, quicker turbo spool, and a deep, muscular sound that doesn’t drone on the highway. This guide provides a complete, step‑by‑step walkthrough for a DIY installation, from gathering the right tools to making final adjustments.

Tools, Materials, and Safety Gear

Before starting, assemble everything you’ll need. Having the right tools on hand prevents frustrating trips back to the workbench and helps ensure a clean installation.

Required Tools

  • ½‑inch drive socket set (metric: 10 mm, 13 mm, 15 mm, 18 mm, 21 mm)
  • Combination wrench set (same sizes)
  • Torque wrench (capable of 20–80 ft‑lb)
  • Breaker bar (18 inch or longer) for stubborn bolts
  • Floor jack and two heavy‑duty jack stands (minimum 3‑ton capacity)
  • Penetrating oil (e.g., WD‑40 Specialist, PB Blaster, Kroil)
  • Rubber mallet or dead‑blow hammer
  • Safety glasses and mechanic’s gloves
  • Shop rags and a catch pan for any fluid drips
  • Wire brush or Scotch‑Brite pad for cleaning flanges
  • Optional: exhaust hanger removal tool (pry‑bar style)

Included in the Borla S‑Type Kit

  • Turbo‑downpipe (front pipe) with integrated flex section
  • Mid‑pipe with resonator (depending on configuration)
  • Muffler section (S‑Type) and tailpipe
  • Exhaust tip(s) with Borla logo
  • All necessary clamps, gaskets, and hardware
  • Installation instruction sheet

Note: Borla kits for the 2019 F‑150 (3.5 L EcoBoost or 5.0 L V8) are vehicle‑specific. Verify the part number against your engine and cab configuration before beginning.

Safety First

  • Work on a flat, level surface in a well‑ventilated area.
  • Disconnect the negative battery terminal to prevent accidental air‑bag deployment or electrical shorts.
  • Allow the exhaust to cool completely – catalytic converters and turbo housings stay hot for hours after driving.
  • Never rely on the floor jack alone; always use jack stands.

Preparation and Vehicle Setup

Proper preparation saves time and prevents mistakes. Follow these steps in order:

  1. Park the truck with plenty of clearance around the rear and sides.
  2. Engage the parking brake and chock the front wheels.
  3. Disconnect the negative battery cable (10 mm bolt) and tuck the terminal away from the post.
  4. Using the floor jack, lift the rear of the vehicle at the differential or frame‑rail reinforced point, then place jack stands under the frame rails – never under the axle. The vehicle should be high enough that you can slide under comfortably.
  5. Spray penetrating oil onto all exhaust flange bolts, O₂ sensor threads, and rubber hanger bushings. Let the oil soak for at least 10 minutes while you review the Borla instructions.

Removing the Factory Exhaust

Working from front to back makes removal easier and reduces the chance of binding components. The stock system is assembled in three main sections: turbo‑downpipe (front pipe), mid‑pipe, and muffler/tailpipe assembly.

Step 1 – Unbolt the Turbo‑Downpipe

Locate the flange connecting the downpipe to the turbine outlet (usually two or four bolts). On the 3.5 L EcoBoost this is near the firewall on the passenger side; on the 5.0 L it’s behind the engine.
Use a 13 mm or 15 mm socket and breaker bar. If bolts are seized, apply more penetrating oil and give each a sharp tap with a hammer. Remove the bolts and free the flange. On EcoBoost models, you may need to temporarily unplug the upstream O₂ sensor to avoid damaging the wiring.

Step 2 – Remove the Mid‑Pipe

The mid‑pipe connects the downpipe to the muffler. On 2019 F‑150s it usually includes a resonator and one or two hangers. Support the pipe with a jack or by hand, then unbolt the downstream flange. Slide the pipe off the hanger bushings using a pry tool or lubricant; do not force the rubber to avoid tearing. Lower the mid‑pipe and set it aside.

Step 3 – Drop the Muffler and Tailpipe

The rear section is supported by two or three rubber hangers and a final flange near the axle. Unbolt the flange (often 15 mm). Then push the hanger rods out of their bushings. The muffler and tailpipe can be removed as a single unit or separated – Borla recommends keeping them together to avoid scratching the paint on the tailpipe. Guide the assembly out from under the truck carefully.

Tip: If the flange bolts are corroded, use a torch (safe only on cool exhaust) or a nut splitter. Replace any fasteners that appear stripped.

Step 4 – Remove and Swap O₂ Sensors

On most 2019 F‑150s, the downstream O₂ sensor is located in the downpipe. Unplug the electrical connector and use an O₂ sensor socket (22 mm or 7/8 inch) to remove it. Transfer the sensor to the new Borla front pipe – apply a thin coat of anti‑seize to the threads. Reconnect the wiring harness.

Installing the Borla S‑Type Turbo‑Back Exhaust

All Borla S‑Type systems are mandrel‑bent from T‑304 stainless steel and designed for a direct fit. Follow the order below for the cleanest assembly.

1. Install the Front Pipe (Turbo‑Downpipe)

Position the new downpipe under the vehicle and align the flange with the exhaust outlet from the turbo. Use the supplied gasket (or the factory gasket if in good condition). Hand‑tighten all bolts, then torque to 35 ft‑lb using a crisscross pattern. Double‑check that the flex section has clearance to the engine cradle and transmission lines.

2. Attach the Mid‑Pipe

Slide the supplied band clamp loosely over the end of the downpipe. Fit the mid‑pipe onto the downpipe slip‑joint, ensuring the alignment tab (if provided) is seated. Connect the mid‑pipe hangers to the factory isolators. Do not fully tighten the band clamp yet – leaving it slightly loose allows for fore/aft adjustment.

3. Mount the Muffler and Tailpipe

Assemble the muffler section to the tailpipe using the supplied three‑bolt flange and gasket. Tighten to 30 ft‑lb. Lift the assembly into place and insert the hanger rods into their rubber bushings. You may need to lubricate the bushings with dish soap or silicone spray. Attach the forward end of the muffler to the mid‑pipe using a band clamp.

4. Position the Exhaust Tip

If the tip is separate, slide it onto the tailpipe and loosely tighten the set screw. Adjust it so it sits evenly in the bumper cutout – about ¾‑inch recessed from the bumper edge is typical for a Borla S‑Type. Once aligned, tighten the set screw to 8 ft‑lb (do not overtighten).

5. Final Torque and Alignment

Starting at the front, torque every clamp and fastener to the spec printed in the Borla instruction sheet – typically 40–50 ft‑lb for V‑band clamps and 15 ft‑lb for smaller slip clamps. While tightening, ensure there is at least ½‑inch clearance to any brake lines, fuel lines, or chassis components. Reposition any hangers that cause contact.

Final Checks and Test Drive

Before lowering the truck, perform these verification steps:

  • Inspect all joints and clamps for gaps – Borla systems seal via overlapping slip‑fits; make sure each clamp is centered.
  • Reconnect the negative battery terminal.
  • Lower the vehicle to the ground (do not drive with jack stands in place).
  • Start the engine and let it idle. Listen for any hisses or rattles. A small amount of smoke from oil residue on the new stainless steel is normal and will burn off.
  • Check underneath for exhaust leaks by feeling for escaping air with your hand (engine cold) or using a soap‑and‑water spray (idle only, no revving).
  • Take a gentle first test drive. Vary the throttle load, listen for drone at highway speeds (the S‑Type is engineered to minimize cabin drone), and confirm no contact at the differential or spare tire.
  • After the first 100 miles, re‑torque all band clamps – thermal cycling can loosen them slightly.

Sound Profile and Performance Expectations

The Borla S‑Type turbo‑back delivers a deep, aggressive growl under acceleration that settles into a quiet, refined idle. At cruising speeds the tone is moderate – not as loud as Borla’s ATAK system, but more authoritative than the stock setup. On the 3.5 L EcoBoost, you’ll notice quicker turbo spool and a sharper exhaust note at full boost. On the 5.0 L V8, the S‑Type amplifies the Coyote’s natural baritone without being obnoxious.

Power gains typically range from 15–25 hp and 20–30 ft‑lb of torque at the wheels when paired with a custom tune. Even without a tune, the reduced backpressure improves throttle response and fuel economy under light throttle. For maximum performance, consider a professional ECU calibration from a reputable tuner like 5 Star Tuning or Livernois Motorsports.

Maintenance and Longevity

Borla’s T‑304 stainless steel is highly corrosion‑resistant, but the polished tips may develop a rainbow heat stain over time. A periodic wipe with stainless steel cleaner and a microfiber cloth keeps them looking new. Inspect the hanger bushings every oil change; replace any that are cracked or stretched. Band clamps should be re‑tightened once a year, especially if you live in an area with road salt.

External Resources

Conclusion

Installing a Borla S‑Type turbo‑back exhaust on a 2019 Ford F‑150 is a rewarding weekend project that transforms the truck’s character. With careful preparation, proper torque values, and attention to alignment, you can achieve a professional‑grade fit that delivers lasting performance and an exhilarating soundtrack. Whether you’re a seasoned DIYer or a first‑time exhaust swapper, this system is designed for a straightforward installation – just follow the steps in order, take your time on rusty hardware, and enjoy the open road with a new note.