INSTRUCTIONS FOR KIT #2004555    SINGLE EXHAUST KIT     

FITS 1997-2003 FULL-SIZE FORD 1/2 & 3/4 TON 2WD & 4WD PICKUPS W/V-8 & 6 CYL. WITH     2-1/2" EXHAUST AT CONVERTER.  THIS KIT FITS ALL WHEEL BASE MODELS AND     SUPER CREW.  DOES NOT FIT DIESEL, V-10, SUPER DUTY OR LIGHTNING.

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

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

NOTE:  THE EXTENSION PIPES 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 EXTENSION PIPE WITH THE MIDDLE EXTENSION PIPE INTO PLACE.  WITH THE TAIL PIPE IN THE REAR OF THE MUFFLER, HOLD UP THE MUFFLER AND TAIL PIPE 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 2-1/2" CLAMP TO ATTACH THE FRONT EXTENSION PIPE TO THE CONVERTER PIPE.  USE A 3” CLAMP TO ATTACH THE MIDDLE EXTENSION PIPE TO THE FRONT EXTENSION PIPE.

4)  USE A 3" MUFFLER CLAMP TO ATTACH THE INLET OF THE MUFFLER (CENTER INLET, SIDE OUTLET) AND THE EXTENSION PIPE TOGETHER.  THE OUTLET OF THE MUFFLER SHOULD LIE TOWARDS THE DRIVE SHAFT OF THE VEHICLE (INSIDE).

5)  INSTALL THE OVER THE AXLE SECTION OF THE TAIL PIPE USING A 3" CLAMP.  ATTACH THIS CLAMP TO THE OUTLET OF THE MUFFLER.  USE A 5/16 X 1" BOLT, NUT, LOCK WASHER, AND FENDER WASHER TO CONNECT A THU-900 SWINGER HANGER TO THE FRAME ABOVE THE CONNECTION OF THE TAIL PIPE AND THE MUFFLER.  IF NO HOLE EXISTS IN THE FRAME, DRILL A 5-16" HOLE  IN THE FRAME ABOVE THIS CONNECTION.  THE INLET OF THE OVER THE AXLE TAIL PIPE HAS A 24 DEGREE BEND, THE OUTLET A 74 DEGREE BEND.  CLAMP THE THU-900 TO THE MUFFLER/PIPE CONNECTION.

6)  INSTALL THE REAR SECTION OF THE TAIL PIPE USING THE 3" CLAMP.    

7)  LOCATE OR DRILL A 5/16" HOLE IN THE FRAME ABOVE THE CONNECTING POINT OF THE OVER THE AXLE PIPE AND THE REAR TAIL PIPE.  USE A 5/16" X 1" BOLT, NUT, LOCK WASHER, AND FENDER WASHER TO CONNECT THE BRACKET (BR3) TO THE FRAME.  USE THE REMAINING BOLT, NUT, LOCK AND FENDER WASHER ASSEMBLY TO CONNECT THE THU-900 HANGER TO THE BRACKET.  CONNECT THE THU-900 HANGER TO THE OVER THE AXLE PIPE/REAR TAIL PIPE CONNECTION.  

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

HARDWARE KIT FOR KIT #2004555
1)  PC250 (2-1/2"  CLAMP)           
1)  OVER THE AXLE TAIL PIPE #2005500-2
4)  3" CLAMP                   
1)  MUFFLER #1142
3)  FENDER WASHERS                
1)  REAR TAIL PIPE #2005500-3    
1)  BR3 (BRACKET)--BR755           
1)  FRONT EXTENSION PIPE
3)  5/16" X 1" BOLTS               
3)  5/16" NUTS                   
1)  MIDDLE EXTENSION PIPE
3)  5/16" LOCK WASHERS            
2)  THU-900 (360 DEG. SWINGER HANGER)--BR91930


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.

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.

 
 
Heartthrob Exhaust Accessories are manufactured in--Litchfield, Mn