INSTRUCTIONS FOR #1024455
FITS 1980-1996 FULL SIZE FORD PICKUP WITH 6 CYLINDER, V8--EXCEPT 460
& 351 C.I. W/2-1/2" EXHAUST AT CONVERTER
NOTE: DO NOT TIGHTEN ANY CLAMPS UNTIL THE LAST STEP!
1) REMOVE THE SPARE TIRE FROM UNDER THE TRUCK.
BECAUSE OF CLEARANCE
PROBLEMS, YOU WILL NOT BE ABLE TO RUN THIS SYSTEM WITH THE SPARE TIRE IN
ITS ORIGINAL POSITION. THEREFORE, IT MUST BE PULLED PERMANENTLY!!!
2) REMOVE EXHAUST SYSTEM LEAVING ONLY THE ORIGINAL Y
PIPE AND CATALYTIC CONVERTER ON THE TRUCK.
NOTE: THE EXTENSION PIPE WILL FIT THE 155" WHEEL BASE
TRUCKS WITHOUT
CUTTING. ON ALL OTHER VEHICLES THE EXTENSION PIPE WILL NEED TO BE
CUT FROM
THE 3" O.D. END (THE END THAT IS NOT SHRUNK) AS NECESSARY.
3) SLIP THE FRONT PIPE INTO PLACE. WITH THE
TAIL PIPES IN THE REAR OF THE
MUFFLER, HOLD UP THE MUFFLER AND TAIL PIPES IN A POSITION THAT CLEARS
ALL
CHASSIS COMPONENTS. MARK THE FRONT PIPE. MAKE SURE TO
ACCOUNT FOR AT
LEAST 2" OF THE PIPE TO GO INTO THE MUFFLER. CUT THE FRONT PIPE.
4) USE A 2-1/4" CLAMP TO ATTACH THE EXTENSION PIPE TO
THE CATALYTIC CONVERTER PIPE.
5) USE A 3" CLAMP TO ATTACH THE MUFFLER (#6842 OR
EQUIVALENT) TO THE EXTENSION PIPE.
6) SLIP THE RIGHT AND LEFT OVER THE AXEL PIPES INTO
MUFFLER.
7) WITH THE MUFFLER AND OVER THE AXEL PIPES IN PLACE,
INSTALL THE TWO THU900
HANGERS ABOVE THE OUTLETS OF THE MUFFLER TO THE FRAME. NOTE: IT
MAY BE NECESSARY TO DRILL 5/16" HOLES IN THE FRAME IF HOLES ARE NOT
PRESENT. USE 5/16” X 1” BOLTS, NUTS, LOCK WASHERS, FENDER WASHERS
TO CONNECT THE HANGERS TO THE FRAME.
8) MOUNT THE MUFFLER AND TAIL PIPES TO THE HANGERS
USING THE 3" CLAMPS (ONE FOR EACH OUTLET OF THE MUFFLER).
9) INSTALL THE 28" LONG 3" I.D./O.D. TAIL PIPE
EXTENSIONS TO THE OVER THE AXEL PIPES.
10) LOCATE MOUNTING HOLES IN THE FRAME NEAR THE END
OF THE OVER THE AXEL
SECTIONS OF THE TAIL PIPES. IF NO MOUNTING HOLES ARE PRESENT,
DRILL A 5/16" HOLE
IN THE FRAME FOR EACH TAIL PIPE. INSTALL THE REMAINING THU900
HANGERS USING
THE FENDER WASHERS, NUTS, BOLTS AND LOCK WASHERS. CLAMP THE
HANGERS TO
THE REAR TAIL PIPE EXTENSIONS, CONNECTING THE TWO PIPES AND THE HANGERS.
11) TRIM TAIL PIPES TO YOUR DESIRED LENGTHS.
12) TIGHTEN ALL CLAMPS AND NUTS AND BOLTS AND CHECK
FOR CLEARANCE OF BRAKE LINES AND CHASSIS COMPONENTS.
HARDWARE FOR #1024455
1) 2-1/4" CLAMP
1) FRONT EXTENSION PIPE #1024455-3
5) 3" CLAMP
1)
LEFT TAIL PIPE #1028350-2
4) FENDER WASHERS 1)
RIGHT TAIL PIPE #1028350-1
4) 5/16" X 1" BOLTS
1) 6842 MUFFLER
4) 5/16" NUTS
2) TAIL
PIPE EXTENSIONS
4) 5/16" LOCK WASHERS
4) THU900 (360 SWINGER) HANGER
DANGER WARNING: Should the purchaser decide to install this, or any
other 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.
INSTRUCTIONS FOR #1024455
NOTES:
-THE LEFT TAIL PIPE HAS 6 BENDS--THE INLET IS THE
LONG END
-THE RIGHT TAIL PIPE HAS 5 BENDS--THE INLET IS THE
SHORT END
-THE MUFFLER OUTLETS SHOULD BOTH BE PARALLEL TO THE
GROUND AND RUN SIDE BY
SIDE