99-02 Ford Expedition/Navigator 4.6L- 5.4L 2/4WD Cat-Back Dual Sport Truck Exhaust Instruction Manual
Lay out the exhaust on the floor so it looks like the drawing and compare parts with manual. To remove the stock exhaust, un-clamp it just in front of the muffler. You may need to heat it up for easier removal. Leave all rubber grommets in place. Use WD-40 to aid in removal of exhaust and the hangers. Now cut off your stock tailpipe just behind the muffler
Install head pipe #A onto your existing stock front pipe and secure with clamp #H. Use a jack stand to support the converter. Do not tighten.
Install muffler #B onto head pipe 1 ½” to 2” with the louvers facing towards the converter. Use a jack stand to support the muffler. Use clamp #J to secure the muffler to the head pipe. Do not tighten. Outlets should be on the bottom.
Install rear mufflerT- hanger #K into rubber grommets located just above the muffler outlets. Shorter side of the hanger will be inserted on the passenger side grommet. Slide clamp onto passenger side muffler outlet. Do not Install the passenger side front tailpipe #E 1 ½” to 2” into muffler. Use clamp # H to secure front tailpipe to muffler, and attach hange # K. Do not tighten.
Install drivers side front tailpipe #C into muffler 1 ½” to 2”. Use clamp #H to secure front tailpipe to muffler. Do not tighten.
Install passenger side overaxle tailpipe #F onto front tailpipe using clamp #I to secure pipes together. Do not tighten. Slide welded hanger into rubber grommet Install drivers side overaxle tailpipe #D onto front tailpipe Use clamp #I to secure together. Do not tighten. Use bolt kit #L to secure pipes together. Tab on drivers’ side tailpipe will be on top.
Install the stainless steel tips. Clamp down. To clean your stainless tips, use a scotch brite pad and any stainless steel or aluminum cleaner. Now go back and tighten all clamps, nuts and bolts. Start from the front and work back.
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