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).