Part #  1007410  w/stainless steel angle cut tips    Part # 
Part #  1007420  w/painted blunt cut tips        Part # 

This muffler-back kit fits ‘01-’03 Ford Explorer Sporttrac, 2WD & 4WD, w/4.0L V6.    
                      
    Heartthrob exhaust systems are manufactured by Heartthrob Exhaust Inc./CREMCO--Litchfield, MN.  Email us at heartthrob@willmar.com for detailed installation pictures.

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:
2)  5/16” nuts                  
1)  2-1/4” hanger clamp-#2875       
2)  5/16” x 1” bolts    
2)  fender washers           
2)  5/16” lock washers                
1)  cable tie            
8)  2-1/4” clamps               
2)  BR91930 swinger hangers                    
2)  muffler tips--stainless or painted       
1)  right tail pipe (5 bends)    -#1004106   
1)  2-1/4” id/od front extension pipe
1)  y-pipe-#0030000             
1)  left tail pipe (5 bends)-#1004107
 















Kit #1007410     #1007420 
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.

NOTE:  Make sure that the vehicle is secured in a safe manner before doing any work underneath the vehicle.  Due to room restrictions over the axle on the driver’s side, you will need to tie off and move some brake and breather lines for clearance of the left side tail pipe (more details will be listed below).  These lines need to be moved in a safe manner!

1)  Cut the o.e. exhaust system at about 3” from the inlet of the o.e. muffler (do not measure from the heat shield).  Remove the old exhaust system from this point back, leaving only the y-pipe, converters, and most of the o.e. extension pipe on the truck, keeping the o.e. rubber hanger mounts in place.  You may need to cut the o.e. exhaust system in two pieces just after the rear resonator to remove it.  

2)  Install the 2-1/4” i.d. end (expanded) of the 2-1/4” front extension pipe to the o.e. extension pipe using a 2-1/4” clamp.  

3)  Install the y-pipe to the 2-1/4” front extension pipe using a 2-1/4” clamp to connect the two pieces.  

4)  Install the right tail pipe (it has 5 bends) to the y-pipe using a 2-1/4” clamp.  Make sure that you have at least 1/2” of clearance from the shock.  Both tail pipes are routed between the shock and the spare tire.

5)  Install the muffler tip onto the right tail pipe using a 2-1/4” clamp (you may trim the tail pipe to length if preferred).  

6)  Install the left tail pipe (5 bends) to the y-pipe using a 2-1/4” clamp.  For installation of the left tail pipe, you will need to make some room.  There is a clip that holds the rear end breather line in place, and this line is in the way, re-hang this line using the same clip and make sure to have plenty of clearance.  There is a cable tie enclosed in this kit, use it to LOOSLEY tie the brake line to the parking brake lines.  Do not tighten the cable tie fully, leave plenty of slack in the tie to allow for movement.  The main thing is to get the brake line away from the left tail pipe, DO NOT TIE THESE LINES TIGHTLY TOGETHER!  You will also need to bend the brake line that runs to the driver’s side rear wheel along the rear differential.  Bend this slightly so as to get it to run just below the very top of the rear differential.  Detailed digital pictures are available, email us at heartthrob@willmar.com.

7)  Install the muffler tip onto the left tail pipe using a 2-1/4” clamp (you may trim the tail pipe to length if preferred).
 
8)  Locate the original hanger mount located above the y-pipe.  Install the 2-1/4” hanger clamp to the o.e. rubber hangers above and connect the clamp to the leg of the y-pipe furthest away from the driveshaft.

9)  Locate the hole in the frame on the left and right side after the rear axle (or drill if one is not present) but before the muffler tips, and install a BR91930 hanger to the frame using the included 5/16” x 1” bolt, nut, lock and fender washer.  You will need to put a 90 degree bend in the portion of the hangers with the holes (we recommend either the third or second hole from the top) to bolt to the frame.

10)  Tighten all clamps, nuts, and bolts.  Check for leaks and for clearance of all brake, fuel, and breather lines, and for clearance of all chassis and frame components.  CHECK FOR CLEARANCE OF ALL LINES ON THE PASSENGER SIDE AGAIN!!  We recommend tack welding the joints (not necessary though).