22003-2006 Ford Super Duty 6.0L Powerstroke Installation Instructions for System
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.
3. Remove the muffler and tail pipe from the OEM rubber hangers. If a hoist is being used the system can be removed in one piece by removing the bottom shock bolt of the passenger side on 03-04 models. 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. If a hoist is not being used you will have to cut the tail pipe behind the muffler and remove the exhaust in two pieces.
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.
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. 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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