INSTRUCTIONS FOR # 1025755
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 REGULAR CAB LONG 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 #1025755
1) FRONT 3” HANGER CLAMP-#2957
1) FRONT EXTENSION PIPE #1025755-1
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