2003-2007 Ford 6.0L Powerstroke Diesel Extended Cab Short & Long Bed Installation Instructions
Removal of Stock System:
1. Apply a penetrating lubricant liberally to all exhaust fasteners, hangers and rubber insulators.
2. Loosen the nut on the band clamp located behind the catalytic converter using a 15mm wrench or socket. See Figure 1.
3. Remove the muffler and tail pipe from the OEM rubber hangers. To remove the system in one piece, on 03-04 models, the bottom shock bolt of the passenger side shock must be removed. This is not required on 05 or 06 models. Separate the stock exhaust at the slip joint located behind the catalytic converter and remove the muffler and tail pipe from under the truck. Re-install the bottom shock bolt.
4. Remove the catalytic converter by removing the two nuts holding the inlet flange together using a 15mm wrench or socket. Retain the nuts for the re-installation of the catalytic converter. See Figure 2
5. Remove the down pipe from the turbo by removing the band clamp using an 11mm socket. Retain the band clamp for the installation of the new down pipe. See Figure 3. Cut the down pipe in front of the transmission cross member to remove. (Note: The stock down pipe can be removed in one piece by removing the transmission cross member. MBRP Inc. recommends that this procedure only be done by qualified, trained professionals using tools and equipment designed to safely carry out this process.)
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