2004400

INSTRUCTIONS FOR KIT #2004400   DUAL KIT

FITS 1980-1996 FULL-SIZE FORD 1/2 & 3/4 TON 2WD & 4WD PICKUPS W/V-8 & 6 CYL. WITH 2-1/4" EXHAUST AT THE CONVERTER. THIS KIT FITS ALL WHEEL BASE MODELS. DOES NOT FIT DIESEL, AND 460 AND 351 C.I. WITH 2-1/2” EXHAUST AT THE CONVERTER.

NOTE: DO NOT TIGHTEN ANY CLAMPS OR BOLTS UNTIL THE LAST STEP!

1) REMOVE THE EXHAUST SYSTEM AT THE CLAMP BEHIND THE CONVERTER LEAVING ONLY THE ORIGINAL Y PIPE, RUBBER MOUNTS, AND CATALYTIC CONVERTER ON THE TRUCK.

NOTE: THE EXTENSION PIPE WILL FIT THE LONGER 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.

2) 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.

3) USE THE 2-1/4" CLAMP TO ATTACH THE EXTENSION PIPE TO THE CONVERTER PIPE.

4) USE THE 3" MUFFLER CLAMP TO ATTACH THE INLET OF THE MUFFLER AND THE EXTENSION PIPE TOGETHER.

5) INSTALL THE LEFT TAIL PIPE. INSTALL THE 2-1/4” WELDED HANGER CLAMP TO THE O.E. RUBBER HANGER MOUNT ABOVE THE LEFT TAIL PIPE JUST AFTER THE MUFFLER. CLAMP THE 2-1/4” WELDED HANGER CLAMP TO THE LEFT TAIL PIPE.

6) INSTALL A 30" I.D/O.D TAIL PIPE EXTENSION TO THE LEFT TAIL PIPE. (YOU WILL WANT TO TRIM THE EXTENSION TO YOUR DESIRED LENGTH.)

7) LOCATE OR DRILL A HOLE IN THE FRAME NEAR THE END OF THE OVER THE AXLE SECTION OF THE LEFT TAIL PIPE ABOVE WHERE THE TAIL PIPE AND EXTENSION PIPE JOIN. USING THE 5/16 X 1" BOLT, NUT, LOCK AND FENDER WASHER, INSTALL THE BR91930 (360 SWINGER HANGER) TO THE FRAME AND ATTACH TO THE LEFT TAIL PIPE USING A 2-1/4" CLAMP (YOU WILL USE THIS SAME CLAMP TO CONNECT THE OVER THE AXLE PIPE AND THE REAR EXTENSION PIPE). NOTE: BOTH TAIL PIPES ARE ROUTED BETWEEN THE SHOCK AND THE SPARE TIRE. THE LEFT TAIL PIPE HAS A 48 DEG. FIRST BEND AND 65 DEG. LAST BEND, AND THE RIGHT TAIL PIPE HAS A 30 DEG. FIRST BEND AND 65 DEG. LAST BEND. THE OUTLETS OF BOTH TAIL PIPES ARE THE LONG ENDS, AND THE LEFT TAIL PIPE IS THE PIPE WITH THE SHORTER INLET.

8) INSTALL THE RIGHT TAIL PIPE USING A 2-1/4" CLAMP TO THE RIGHT OUTLET OF THE MUFFLER.

9) INSTALL A 30" I.D/O.D TAIL PIPE EXTENSION TO THE RIGHT TAIL PIPE. (YOU WILL WANT TO TRIM THE EXTENSION TO YOUR DESIRED LENGTH.)

10) LOCATE OR DRILL A HOLE IN THE FRAME NEAR THE END OF THE OVER THE AXLE SECTION OF THE RIGHT TAIL PIPE ABOVE WHERE THE TAIL PIPE AND EXTENSION PIPE JOIN. USING THE 5/16" X 1" BOLT, NUT, LOCK AND FENDER WASHER, INSTALL THE BR91930 (360 SWINGER HANGER) TO THE FRAME AND CONNECT TO THE JUNCTION OF THE RIGHT TAIL PIPE AND REAR EXTENSION PIPE USING A 2-1/4" CLAMP.

11) TIGHTEN ALL CLAMPS AND BOLTS AND CHECK FOR CLEARANCE OF THE FRAME, BODY, AND BRAKE AND FUEL LINES.

HARDWARE KIT FOR KIT #2004400:
1) FRONT EXTENSION PIPE #2004400-1
1) LEFT TAIL PIPE #2004400-2
1) RIGHT TAIL PIPE #2004500-3
2) TAIL PIPE EXTENSIONS
1) MUFFLER #907

1) 3" CLAMP
5) 2-1/4" CLAMPS
2) (360 SWINGER HANGER)-BR91930
2) 5/16" X 1" BOLT
2) 5/16" NUT
2) FENDER WASHER
2) 5/16" LOCK WASHER
1) 2-1/4” WELDED HANGER CLAMP-#2906

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.

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.