INSTRUCTIONS FOR #  1025750
FITS 1999-2004 FULL SIZE GM PICKUP WITH 2-3/4" FLANGED EXHAUST AT THE CONVERTER—4.3L V6, 4.8L & 5.3L V8 AND EXTENDED CAB SHORT BOX ONLY
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)    UNBOLT THE ORIGINAL EXHAUST SYSTEM AFTER THE FLANGE BEHIND THE CONVERTER Y-PIPE AND SAVE THE NUTS.  DISCONNECT THE FACTORY HANGERS FROM THE ORIGINAL SYSTEM, LEAVING THE RUBBER HANGER MOUNTS IN PLACE.  REMOVE THE ORIGINAL SYSTEM FROM THE VEHICLE.  

3)  SLIP THE INCLUDED FORMED FLANGE ON THE FRONT EXTENSION PIPE (3” PIPE WITH A BALL FLARE ON ONE END).  THE FLAT SIDE OF THE FORMED FLANGE GOES TOWARDS THE FRONT OF THE VEHICLE.  YOU MAY NEED TO TAP THE FLANGE ON THE BALL JOINT WITH A HAMMER TO INSTALL.  ROTATE THE PIPE TO CLEAR THE CROSS MEMBER AND INSTALL THE ORIGINAL NUTS LOOSELY ON THE FLANGE.

4)    INSTALL THE FRONT 3” HANGER CLAMP TO THE FRONT O.E. RUBBER HANGER MOUNT.  CLAMP THIS HANGER TO THE 3” FRONT EXTENSION PIPE.

5)    USE A 3" CLAMP TO ATTACH THE MUFFLER (#6842 OR EQUIVALENT) TO THE EXTENSION PIPE.

6)    INSTALL THE LEFT TAIL PIPE (6 BENDS, THE INLET IS THE LONG END) TO THE MUFFLER USING A 3” CLAMP.  THE LEFT TAIL PIPE GOES BETWEEN THE SPRING AND THE SHOCK.  INSTALL THE MIDDLE 3” HANGER CLAMP TO THE LEFT TAIL PIPE BEFORE THE FIRST BEND IN THE PIPE AND CONNECT TO THE O.E. RUBBER MOUNT ABOVE.

7)    INSTALL THE LEFT TAIL PIPE EXTENSION TO THE LEFT TAIL PIPE.  LOCATE OR DRILL A 5/16” HOLE IN THE FRAME ABOVE THE CONNECTING POINT OF THE TAIL PIPE AND THE TAIL PIPE EXTENSION AND INSTALL A BR91930 SWINGER HANGER TO THE FRAME.  USING THE INCLUDED HARDWARE, BOLT THE BR91930 SWINGER HANGER TO THE FRAME AND CLAMP TO THE CONNECTING POINT OF THE TAIL PIPE AND THE TAIL PIPE EXTENSION USING A 3” CLAMP.  

8)    INSTALL THE RIGHT TAIL PIPE (5 BENDS, THE INLET IS THE SHORT END) TO THE MUFFLER USING A 3” CLAMP.  INSTALL THE REAR 3” HANGER CLAMP TO THE O.E. RUBBER MOUNT AND CLAMP TO THE RIGHT TAIL PIPE IN THE LAST BEND.

9)    INSTALL RIGHT TAIL PIPE EXTENSION TO THE RIGHT TAIL PIPE USING A 3” CLAMP.

10)    TRIM TAIL PIPES TO YOUR DESIRED LENGTHS.

11)    TIGHTEN ALL CLAMPS AND NUTS AND BOLTS AND CHECK FOR CLEARANCE OF BRAKE  AND FUEL LINES AND CHASSIS COMPONENTS.


HARDWARE FOR #1025750
1)  FRONT 3” HANGER CLAMP-#2944        1)  FRONT EXTENSION PIPE #1025750-1
5)  3" CLAMP                                                    1)  LEFT TAIL PIPE #1028350-2
1)  FENDER WASHERS                                    1)  RIGHT TAIL PIPE #1028350-1
1)  5/16" X 1" BOLTS                                        1)  6842 MUFFLER
1)  5/16" NUTS                                                2)  TAIL PIPE EXTENSIONS
1)  5/16" LOCK WASHERS
1)  FORMED FLANGE
1)  MIDDLE 3” HANGER CLAMP-#2911
1)  REAR 3” HANGER CLAMP-#2912
1)    (360 SWINGER) HANGER—BR91930

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.

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