Part # 1007080 w/stainless steel angle cut
tips Part #
Part # 1007090 w/painted blunt cut tips
Part #
Kit fits ’04 full-size Ford « ton pickup, 2WD & 4WD, all wheel
bases, w/4.6L & 5.4L V8, except for Harley Davidson,
Lightning, and Super Duty. For vehicles only with 2-1/2” exhaust
at the
converter.
Heartthrob exhaust systems are manufactured by
Heartthrob Exhaust--Litchfield, MN
For detailed digital installation photos email us at
heartthrob@willmar.com
DANGER WARNING: Should the purchaser decide to install this
exhaust product at home, be warned that pleasure car or light duty
truck/van “bumper” jacks are intended for emergency use only. The
use of frame contact jack stands in conjunction with a floor jack as
main support is highly recommended to minimize accidental dropping of a
vehicle while the installation proceeds.
Limitation of liability--Disclaimers: The regulation of emissions
production, noise levels and safety standards is undertaken by the
federal government, each of the fifty state legislatures, and by many
local municipalities, towns and counties.
The manufacturer makes no warranties of
merchantability, of fitness for a particular purpose, or that its
products are approved for general use, or that its products comply with
laws, regulations or ordinances in the states where they may be sold to
the ultimate purchaser, the consumer.
The entire risk as to the conformity of this product
in any such state and as to repair, should the product prove to be
defective or non-conforming, is on the retail purchaser, the buyer, the
ultimate consumer of such product and it is not upon the seller,
distributor, or manufacturer.
In this connection, retail purchaser, the buyer, the
ultimate consumer assumes the burden of the entire cost of any and all
necessary service, alterations, and or repair.
The foregoing statement limits the liability of the
manufacturer.
HARDWARE KIT:
1) 5/16” nuts
1) 5/16” x 1” bolts
1) fender
washers
1 5/16” lock washers
5) 2-1/4” clamps
2) 2-1/2” clamps
1) rear 2-1/4” hanger clamp-#2862
1) BR91930 swinger hanger
1) 2-1/2” hanger clamp-# 2864
1) front 2-1/4” hanger clamp-#2863
2) muffler tips--stainless or painted
1) right tail pipe
1) 2-1/2” x 48” extension pipe
1) y-pipe--#0030017
1) left front tail pipe
1) left rear tail pipe
Kit #1007080 #1007090
INSTRUCTIONS:
NOTE: do not tighten any clamps or nuts and bolts until the last
step!! Before cutting any pipes it is a good idea to lay out all
the included pipes along side the vehicle and get a good idea of how
the pipes will hang on the vehicle. Please read the instructions
fully and thoroughly before you begin.
1) Remove the old exhaust system at the outlet after the
converter y-pipe, leaving only the y-pipe, converters, and o.e. rubber
hanger mounts on the truck.
2) NOTE: Do not trim the 48” long extension pipe until you
are satisfied that you have the proper measurements. The extension pipe
will fit the 163” wheel base models without cutting. For those
with shorter wheel base models, you will need to trim as follows from
the o.d. end (non-expanded end):
126” w.b. (regular cab
6-1/2’ medium box)
cut to 11”
132.5” w.b. (super cab 5-1/2’
short box)
cut to 17.5”
138.5” w.b. (supercrew 5-1/2’
short box)
cut to 23.5”
144.5” w.b. (regular cab 8’ long
box, super cab 6-1/2’ medium box) cut to 29.5”
163” w.b. (super cab 8’ long
box)
no cutting
required
3) Install the i.d. end of the extension pipe to the converter
y-pipe using a 2-1/2” clamp. Install the y-pipe to the extension
pipe, using a 2-1/2” clamp to connect the two pieces. Make sure
that the y-pipe is mounted parallel to the ground, the y-pipe has
offsetting bends that should raise the exhaust up towards the truck
bed.
3) Install the 2-1/2” hanger clamp to the front extension pipe or
y-pipe at the o.e. rubber hanger mount along side the extension or
y-pipe.
4) Install the i.d. end of the right tail pipe (it has 5 bends)
to the outlet of the y-pipe using a 2-1/4” clamp. Install the
rear 2-1/4” hanger clamp to the right front tail pipe just after the
rear axle, and below the o.e. rubber hanger mount. Install the
wire portion of the rear 2-1/4” hanger clamp to the o.e. mount
above.
5) Install a muffler tip onto the right rear tail pipe. Use
a 2-1/4” clamp to secure the tip to the rear tail pipe.
6) Install the left front tail pipe (4 bends) to the y-pipe using
a 2-1/4” clamp, making sure that you have clearance between the rear
brake line (bend bracket to the front if necessary) and spare
tire.
7) Install the left rear tail pipe (1 bend) to the left front
tail pipe using a 2-1/4” clamp. On some models you will need to
trim the rear tail pipe to length. Mark where you want to cut the
left rear tail pipe by holding up a tip next to the rear tail
pipe. Trim the rear tail pipe to length. Install the
muffler tip onto the left rear tail pipe. Use a 2-1/4” clamp to
secure the tip to the rear tail pipe.
8) Locate the mounting hole (or drill if one is not present)
directly above the connecting point of the left front tail pipe and the
left rear tail pipe and mount the hanger using the included hardware
for the left tail pipe. You will need to put a bend in the hanger
to mount it to the bottom of the frame. Attach the hanger to the
left front and rear tail pipe using a 2-1/4” clamp.
9) Tighten all clamps, nuts, and bolts. Check for leaks and
for clearance of all brake and fuel lines, and for clearance of all
chassis and frame components. We recommend tack welding the
joints (not necessary though).