INSTRUCTIONS FOR KIT #2004660 DUAL KIT
FITS 2004 FULL-SIZE FORD ½ TON 2WD & 4WD PICKUPS W/4.6L,
5.4L V-8 WITH 2-1/2" EXHAUST AT CONVERTER. THIS KIT FITS ALL
WHEEL BASE MODELS. DOES NOT FIT DIESEL, V-10, LIGHTNING OR SUPER
DUTY.
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.
2) NOTE: BOTH OF THE EXTENSION PIPES WILL FIT THE LONG
WHEEL BASE TRUCKS (163” W.B., SUPER CAB 8’ BOX) WITHOUT CUTTING.
FOR 144.5” W.B. (SUPER CAB 6-1/2’ BOX, AND REGULAR CAB 8’ BOX), YOU
WILL NEED BOTH EXTENSION PIPES, BUT TRIM THE 3” MIDDLE (ID/OD 3” X 27”
LONG STRAIGHT PIECE) EXTENSION PIPE TO A TOTAL LENGTH OF 8.5” LONG, CUT
FROM THE OD END (NON EXPANDED END). FOR 138.5” W.B. (SUPER CREW
5-1/2’ BOX), USE ONLY THE 3” FRONT (2-1/2” ID/3” OD X 40” LONG)
EXTENSION PIPE, NO CUTTING NECESSARY. FOR 132.5” W.B. (SUPER CAB
5-1/2’ BOX), USE ONLY THE 3” FRONT EXTENSION PIPE TRIMMED TO A TOTAL
LENGTH OF 34”, TRIM FROM THE 3” OD END. FOR 126” W.B. (REGULAR
CAB 6-1/2’ BOX), USE ONLY THE 3” FRONT EXTENSION PIPE TRIMMED TO A
TOTAL LENGTH OF 27.5”, TRIM FROM THE 3” OD END.
3) USE THE 2-1/2" CLAMP TO ATTACH THE 3” FRONT EXTENSION PIPE TO
THE CONVERTER PIPE, THOSE WITH 126” AND 132.5” W.B., TRIM THE 3” FRONT
EXTENSION PIPE TO LENGTH AS DESCRIBED IN STEP 2).
4) THOSE WITH 144.5” AND 163” W.B., ATTACH A PRE-CUT 3” MIDDLE
EXTENSION PIPE TO THE 3” FRONT EXTENSION PIPE USING A 3” CLAMP.
USE THE 3” HANGER CLAMP ON THE 3” FRONT EXTENSION PIPE TO CONNECT THE
3” FRONT EXTENSION PIPE TO THE O.E. RUBBER HANGER MOUNT ALONG SIDE THE
SYSTEM.
5) USE A 3" MUFFLER CLAMP TO ATTACH THE INLET OF THE MUFFLER AND
THE EXTENSION PIPE TOGETHER.
6) INSTALL THE LEFT FRONT TAIL PIPE (4 BENDS) USING A 2-1/4"
CLAMP TO THE LEFT OUTLET OF THE MUFFLER.
7) INSTALL THE LEFT REAR TAIL PIPE (1 BEND) TO THE LEFT FRONT
TAIL PIPE USING A 2-1/4” CLAMP.
8) INSTALL THE 2-1/4” FRONT HANGER CLAMP TO THE LEFT FRONT TAIL
PIPE JUST BEFORE THE FIRST BEND, AND CONNECT THE WIRE PORTION OF THE
HANGER TO THE O.E. RUBBER HANGER MOUNT ABOVE.
9) LOCATE OR DRILL A HOLE IN THE FRAME NEAR WHERE THE LEFT FRONT
AND REAR TAIL PIPES CONNECT. USING THE 5/16 X 1" BOLT, NUT, LOCK
AND FENDER WASHER, INSTALL A BR91930 HANGER TO THE FRAME AND ATTACH TO
THE LEFT TAIL PIPE USING A 2-1/4" CLAMP. YOU WILL NEED TO PUT A
BEND IN THE HANGER TO MOUNT IT TO THE BOTTOM OF THE FRAME.
10) INSTALL THE RIGHT FRONT TAIL PIPE USING A 2-1/4" CLAMP TO THE
RIGHT OUTLET OF THE MUFFLER. INSTALL THE RIGHT REAR TAIL PIPE TO
THE RIGHT FRONT TAIL PIPE USING A 2-1/4” CLAMP.
11) INSTALL THE 2-1/4” REAR HANGER CLAMP TO THE RIGHT FRONT TAIL
PIPE JUST AFTER THE AXLE, AND BELOW THE O.E. RUBBER HANGER MOUNT,
CONNECT THE WIRE PORTION OF THE HANGER TO THE MOUNT.
12) INSTALL THE RIGHT REAR TAIL PIPE TO THE RIGHT FRONT TAIL PIPE
USING A 2-1/4” CLAMP.
13) TIGHTEN ALL CLAMPS AND BOLTS AND CHECK FOR CLEARANCE OF THE
FRAME, BODY, CHASSIS COMPONENTS, AND BRAKE AND FUEL LINES.
HARDWARE KIT FOR KIT #2004660 #:
1) 3” FRONT EXTENSION PIPE #
1) 2-1/2" CLAMP
1) LEFT FRONT TAIL PIPE #
2) 3" CLAMPS
1) RIGHT FRONT TAIL PIPE #
4) 2-1/4" CLAMPS
1) LEFT REAR TAIL PIPE #
1) 360 SWINGER
HANGER--BR91930
1) MUFFLER #907
1) 5/16" X 1" BOLT
1) RIGHT REAR TAIL PIPE #
1) 5/16" NUT
1) 3” MIDDLE EXTENSION PIPE #
1) FENDER WASHER
1) 5/16" LOCK WASHER
1) 3” HANGER CLAMP # 2861
1) 2-1/4” FRONT HANGER CLAMP # 2860
1) 2-1/4” REAR HANGER CLAMP # 2862
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, THE 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.
CALIFORNIA VEHICLE CODE SECTION 27156 PROHIBITS THE
ADVERTISING, OFFERING FOR SALE, OR INSTALLATION OF ANY DEVICE WHICH
MODIFIES A VEHICLE’S EMISSION CONTROL SYSTEM. THIS PRODUCT
IS THEREFORE NOT LEGAL FOR SALE OR USE IN CALIFORNIA ON VEHICLES
EQUIPPED WITH CATALYTIC CONVERTERS.
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.