2003-2007 Ford 6.0L F250-F350 4″ Installation Instructions
Removal of Original System
We suggest that a trained professional remove and install your exhaust.
1) Start under the vehicle. Remove the band clamp that holds the stock system to the converter by loosening the bolt and gently prying the clamp loose. If the clamp will not release continue to next step. When you have the rest of the system off shake the pipe from underneath the vehicle this will break the seal and you will here the clamp release. Gently remove the clamp and save for the reinstallation.
2) Remove the band clamp that holds the stock system to the converter by loosening the bolt and prying the clamp loose. Do not cut when installing on longer models.
3) Cut the original system just behind the muffler.
4) Spray the stock hangers with aerosol lube and pry rubber mounts from the system. Leave the rubber mounts attached to the truck for re-use.
5) Remove the old system from the cat back.
6) Loosen the bolts that hold the converter to the stock down pipe. Remove the converter and keep for reinstall. You must reinstall the converter.
7) Remove the Stock down pipe. You may need to cut it or remove the transmission mount to get enough room. Stop and think before you do either of these a mistake at this time could be very costly.
Installation of New Performance System
(Do not fully tighten any clamps until the complete system is installed and aligned.)
1) From under the truck, install the down pipe with the stock clamp to the turbo. Tighten clamp so you still have some movement.
2) Install the down pipe extension with a clamp.
3) Reinstall the converter to the down pipe extension with a gasket (not pictured).
4) Hang the muffler in the stock location using the hanger clamp on the outlet. This determines the placement of the rest of the system.
5) Install the first tail pipe into the outlet of the muffler using the hanger clamp already installed. Rotate the pipe as needed to pass next to the shock absorber and over the rear axle.
6) Install the second tail pipe into the outlet of the first tail pipe with a clamp. Rotate as needed to level the outlet behind the rear tire. Attach the hanger clamp in the stock location.
7) Measure between the outlet of the converter and the inlet of the muffler. Add 5” to this measurement for the slip-joints and cut the intermediate pipe to fit. Install the cut pipe between the converter and the muffler with a clamp at front and a clamp on the muffler inlet. Install the hanger clamp in the stock location near the front of the intermediate pipe and install the hanger clamp in the stock location near the rear of the intermediate pipe.
8) Starting at the turbo, align and tighten all the pipes and clamps. Start the engine and check for leaks
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