Upgrading your Ford F-250's exhaust system is one of the most effective ways to enhance both its performance and sound profile. The stock exhaust, while functional, is often restrictive and muffled, limiting horsepower, torque, and acoustic character. Among the many aftermarket options available, the Borla ATAK exhaust system stands out as a top-tier upgrade. Engineered for power, durability, and an aggressive, race-inspired tone, the Borla ATAK exhaust transforms your truck's driving experience—delivering deep, throaty rumble and improved exhaust flow without sacrificing quality.

This comprehensive guide will walk you through the entire process of replacing your Ford F-250’s stock exhaust with a Borla ATAK system. From gathering the necessary tools and preparation steps to detailed installation instructions and post-installation tips, you’ll gain the confidence and knowledge to perform this upgrade yourself. Whether you’re a seasoned mechanic or a DIY enthusiast, these step-by-step directions will ensure a smooth, safe, and successful installation.

Why Choose the Borla ATAK Exhaust for Your Ford F-250?

The Borla ATAK (Acoustically Tuned Applied Kinetics) exhaust system is designed for those seeking an aggressive, performance-oriented exhaust note combined with proven engineering and build quality. Made from high-grade 409 stainless steel, the ATAK system offers superior corrosion resistance and longevity compared to the factory exhaust. Its straight-through muffler design minimizes backpressure, promoting enhanced exhaust flow which leads to increased horsepower and torque gains.

Unlike conventional mufflers, the ATAK system utilizes advanced acoustical engineering to produce a loud, deep, and resonant exhaust sound that turns heads but avoids unpleasant drone during highway cruising. This makes it a favorite among truck enthusiasts who want a track-inspired growl without sacrificing daily driveability. Additionally, the Borla ATAK exhaust is designed as a direct bolt-on replacement, ensuring a perfect fit and simplified installation.

Tools and Materials Needed

Before beginning the installation, gather all necessary tools and materials to ensure the process goes smoothly:

  • Socket set and ratchet: Typically, 10mm, 13mm, and 15mm sockets are needed for exhaust bolts and clamps.
  • Wrench set: Combination wrenches will help reach tight spaces.
  • Exhaust hanger removal tool: This specialized tool eases the removal of rubber hangers without damage.
  • Lubricant spray (WD-40 or similar): Helps loosen rusted or tight bolts and rubber hangers.
  • Jack and jack stands: To safely lift and support the truck for access underneath.
  • Protective gloves and eyewear: Safety is paramount when working under your vehicle.
  • Borla ATAK exhaust kit: Verify that your kit matches your F-250’s model year and engine type.
  • Torque wrench: Recommended for tightening bolts to manufacturer specifications.
  • Rubber mallet or hammer: Useful for persuading stuck exhaust components.
  • Safety blocks or wheel chocks: To prevent the truck from rolling during the lift.

Preparation

Proper preparation is critical for an efficient and safe installation. Follow these steps before beginning:

  • Park your truck on a level surface: Choose a flat driveway or garage floor to ensure stability.
  • Engage the parking brake and place wheel chocks: Prevent any movement while working under the vehicle.
  • Allow the exhaust to cool completely: Working on a hot exhaust can cause burns.
  • Lift the rear of the vehicle: Use a hydraulic jack to raise the truck’s rear end, then secure it firmly with jack stands. Never rely solely on the jack.
  • Wear protective gloves and safety glasses: Guard against sharp edges, rust, and debris.
  • Inspect the new Borla ATAK exhaust: Lay out all components and ensure nothing is missing or damaged. Familiarize yourself with the parts and their intended placement.

Removing the Stock Exhaust

Removing the factory exhaust system requires patience and careful attention to avoid damaging surrounding components. Follow these detailed steps:

Step 1: Apply Penetrating Lubricant

Spray WD-40 or an equivalent penetrating lubricant onto all bolts, nuts, and clamps connecting the stock exhaust system. This reduces corrosion and eases removal. Allow the lubricant to soak in for 10-15 minutes for best results.

Step 2: Disconnect the Exhaust from the Catalytic Converter

Locate the flange or clamp connecting the exhaust pipe to the catalytic converter. Using the appropriate socket or wrench, loosen and remove the bolts or clamps. Some models may have a gasket between the flange surfaces—inspect it for damage and replace if necessary during reinstallation.

Step 3: Remove Exhaust Hangers

The exhaust system is supported by rubber hangers mounted to metal brackets on the truck’s frame. Using the exhaust hanger removal tool, gently pry the hangers off their supports. If they are stubborn, apply additional lubricant and wiggle gently to avoid tearing the rubber.

Step 4: Lower the Exhaust System

With all connections detached, carefully lower the stock exhaust system. It may be heavy and awkward—having a helper makes this step safer and more manageable. Set the removed exhaust aside for disposal or recycling.

Additional Tips for Removal

  • Work systematically: Start from the rear and move forward to avoid unnecessary strain.
  • Inspect surrounding components: Check for cracked hangers or damaged heat shields and address as needed.
  • Keep hardware organized: Store bolts, nuts, and clamps safely if you plan to reuse any.

Installing the Borla ATAK Exhaust

With the stock exhaust removed, installation of the Borla ATAK system can begin. This process requires careful alignment and secure fastening to ensure optimal performance and longevity.

Step 1: Compare New Parts to Old

Before installation, lay out the Borla ATAK components side-by-side with the stock exhaust parts. Confirm that pipe lengths, bends, and mounting points match. This ensures proper fitment and helps familiarize you with the assembly order.

Step 2: Attach Exhaust to Catalytic Converter or Mid-Pipe

Start at the front of the exhaust system by connecting the Borla ATAK pipe to the catalytic converter or factory mid-pipe (depending on your truck’s configuration). Use the supplied Borla clamps and hardware to secure the connection, but initially tighten bolts only finger-tight to allow for adjustments during alignment.

Step 3: Mount Exhaust Hangers

Carefully slide the Borla exhaust’s rubber hangers onto the truck’s metal hangers. Proper support prevents excessive movement and reduces stress on welds and joints. Ensure hangers are seated fully and securely.

Step 4: Assemble Remaining Exhaust Sections

Connect the muffler, mid-pipes, and tailpipes in sequence, sliding pipe ends together as designed. Use the provided clamps to loosely secure each joint. Check alignment frequently to maintain proper clearance from the frame, suspension components, and drive shaft.

Step 5: Align and Secure the Exhaust System

Once all components are loosely installed, double-check the entire system’s positioning. The pipes should have at least half an inch of clearance from any vehicle parts to avoid heat damage or vibration transfer. Adjust the hangers and clamps as needed to achieve ideal alignment.

Step 6: Tighten Bolts and Clamps

With everything in place, use a torque wrench to tighten all bolts and clamps to Borla’s specified torque values. This ensures a secure, leak-free seal and prevents hardware from loosening over time.

Additional Installation Tips

  • Use anti-seize compound: Apply to bolt threads to prevent future rust and ease removal.
  • Check gasket condition: Replace any exhaust gaskets with new ones to ensure airtight seals.
  • Verify tailpipe clearance: Ensure the exhaust tips extend properly beyond the bumper without contacting bodywork.
  • Inspect welds and joints: Look for any signs of damage or defects before final tightening.

Final Checks and Testing

After installation is complete, perform the following checks to verify a successful upgrade:

Step 1: Lower the Vehicle

Carefully remove the jack stands and lower your Ford F-250 back to the ground. Remove wheel chocks and ensure the truck is stable.

Step 2: Start the Engine and Inspect for Leaks

With the engine running, listen closely for any exhaust leaks, which often sound like hissing or popping near joints. Feel around clamp connections for escaping gases (be cautious of hot surfaces). Tighten any loose clamps as necessary.

Step 3: Check for Rattling or Vibrations

Shake the exhaust lightly by hand to detect any rattling or loose components. Confirm that the exhaust is firmly mounted and all hangers are supporting the weight properly.

Step 4: Test Drive

Take your F-250 on a short road test. Pay attention to the exhaust note, throttle response, and overall driving feel. The Borla ATAK system should provide a noticeable increase in volume and aggression without drone or harshness. Acceleration should feel more responsive due to improved flow.

Step 5: Post-Installation Inspection

After your initial test drive, inspect the system once more for any signs of shifting or leaks. It’s common for exhaust components to settle slightly during the first few heat cycles. Retighten clamps and bolts as necessary to maintain a secure fit.

Maintenance and Longevity Tips

To keep your Borla ATAK exhaust performing optimally and looking great for years to come, consider these maintenance tips:

  • Regularly inspect mounting hardware: Vibrations from driving can loosen clamps and bolts over time.
  • Clean exhaust tips periodically: Use metal polish or mild cleaners to maintain shine and prevent buildup.
  • Avoid harsh off-road conditions: Excessive mud, rocks, or debris can damage the exhaust surface.
  • Address leaks promptly: Early detection prevents damage to surrounding components and maintains performance.
  • Store the vehicle properly: If not in use for extended periods, consider rust inhibitors to protect exposed metal surfaces.

Common Questions About Borla ATAK Exhaust Installation

Will installing a Borla ATAK exhaust void my warranty?

In most cases, aftermarket exhaust systems do not void the manufacturer’s warranty unless they cause damage to the vehicle. It’s advisable to check Ford’s warranty terms and consult your dealer if concerned.

Can I install the Borla ATAK exhaust myself?

Yes, the Borla ATAK exhaust is designed as a direct bolt-on replacement with detailed instructions, making it suitable for DIY installation with basic mechanical skills and tools. However, if you’re uncomfortable working under your vehicle, professional installation is recommended.

Does the Borla ATAK affect fuel economy?

The improved exhaust flow can lead to a slight increase in fuel efficiency due to better engine breathing, but any gains are generally modest.

Borla designs their exhaust systems to comply with emissions and noise regulations in most regions. However, laws vary by location, so verify local ordinances before installation.

Conclusion

Replacing your Ford F-250’s stock exhaust with a Borla ATAK system is a rewarding upgrade that delivers enhanced engine performance, a bold and aggressive exhaust tone, and long-lasting durability. With proper tools, preparation, and attention to detail, you can complete the installation yourself and enjoy the unmistakable sound and power gains that Borla is known for.

Following this guide will help ensure a smooth installation process from start to finish. Remember to take your time, prioritize safety, and double-check all connections. After installation, enjoy the roar of your Ford F-250 as it commands attention on the road and off.