INSTRUCTIONS FOR KIT #4004555           4” DIESEL KIT TURBO-BACK KIT           

FITS: 1999-2003 FULL-SIZE FORD 3/4 & 1 TON F SERIES W/7.3L POWERSTROKE TURBO DIESEL, 2WD & 4WD, ALL WHEEL BASES, THIS IS A TURBO-BACK EXHAUST KIT, FOR VEHICLES WITHOUT CATALYTIC CONVERTER. 

NOTE:  DO NOT TIGHTEN ANY CLAMPS OR BOLTS UNTIL THE LAST STEP!  READ THESE INSTRUCTIONS FULLY AND THOROUGHLY BEFORE YOU BEGIN.

1)  REMOVE THE EXHAUST SYSTEM AT THE V-BAND CLAMP AT THE TURBO.  REMOVE THE WIRE HANGERS FROM THE O.E. RUBBER HANGER MOUNTS (A LUBRICANT MAY BE NECESSARY), BUT LEAVE THESE RUBBER HANGER MOUNTS ON THE TRUCK.  DISCONNECT THE CLAMPS AT THE REAR OF THE O.E. DOWN PIPE AND AT THE INLET OF THE MUFFLER.  YOU WILL NEED TO CUT YOUR ORIGINAL SYSTEM APART TO REMOVE IT MORE EASILY FROM THE VEHICLE.  YOU WILL NEED TO RE-USE THE ORIGINAL V-BAND CLAMP AT THE TURBO. 

2)  INSTALL THE DOWN PIPE TO THE TURBO AND INSTALL THE ORIGINAL V-BAND CLAMP.  TIGHTEN ONLY ENOUGH TO HOLD IN PLACE. 

3)  INSTALL THE FRONT EXTENSION PIPE TO THE DOWN PIPE USING A 4” CLAMP.  IT IS THE EXTENSION PIPE WITH 3 SHALLOW BENDS IN IT, ID END IS THE INLET.  INSTALL THE FRONT HANGER CLAMP  TO THE FRONT EXTENSION PIPE BETWEEN THE SECOND AND THIRD BENDS, AND INSTALL THE WIRE PORTION OF THE HANGER TO THE O.E. MOUNT ALONG SIDE THE FRONT EXTENSION PIPE.

4)  BOTH OF THE MIDDLE AND REAR EXTENSION PIPES WILL FIT THE CREW CAB LONG BOX MODELS WITHOUT CUTTING.  ON THE OTHER CAB MODELS, YOU WILL NOT NEED THE 16-1/2” (SHORTER) EXTENSION PIPE.  YOU MAY NEED TO TRIM THE EXTENSION PIPES TO LENGTH IF YOU DO NOT HAVE A CREW CAB.

5)  USE A 4" CLAMP TO ATTACH THE 16-1/2” MIDDLE EXTENSION PIPE TO THE DOWN PIPE (FOR CREW CAB MODELS ONLY, OTHER MODEL TRUCKS SKIP THIS STEP).

6)  ATTACH THE 34” REAR EXTENSION PIPE (CUT TO LENGTH IF NECESSARY) TO THE MIDDLE EXTENSION PIPE USING THE REMAINING FRONT HANGER CLAMP.  ATTACH THE WIRE PORTION TO THE O.E. MOUNT BESIDE IT.

7)  INSTALL THE MUFFLER TO THE EXTENSION PIPE USING A 4” CLAMP.  NOTE:  THE EXHAUST SHOULD FLOW OVER, AND NOT DIRECTLY INTO, THE LOUVERS OF THE MUFFLER.

8)  INSTALL THE TAIL PIPE TO THE MUFFLER USING THE FRONT TAIL PIPE 4” HANGER CLAMP (TWO WIRE HANGERS ON IT) AT THE CONNECTING POINT OF THE TAIL PIPE AND MUFFLER.  INSTALL THE WIRE HANGERS THAT ARE ON THE HANGER CLAMP TO THE O.E. RUBBER MOUNTS ABOVE. 

9)  INSTALL THE REAR TAIL PIPE 4” HANGER CLAMP TO THE TAIL PIPE BEFORE THE LAST BEND AND BELOW THE O.E. RUBBER HANGER MOUNT.  INSTALL THE WIRE PORTION OF THE HANGER TO THE O.E. MOUNT ABOVE.

10)  FOR THOSE WITH DUALLY MODELS, YOU WILL NEED TO INSTALL THE TAIL PIPE EXTENSION TO THE TAIL PIPE USING BY EITHER WELDING (RECOMMENDED FOR APPEARANCE REASONS) OR USING A 4” CLAMP (INCLUDED).  YOU MAY NEED TO TRIM TO LENGTH AND STYLE OF CUT.

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

HARDWARE KIT FOR KIT #4004555:

1)  DOWN PIPE # 4004556                                  4)  4” CLAMPS #MC7400

1)  FRONT EXTENSION PIPE #4004557                          1)  REAR 4” HANGER CLAMP # 2995

1)  16-1/2” MIDDLE EXTENSION PIPE # 4004558         2)  FRONT 4” HANGER CLAMP # 2997

1)  34” REAR EXTENSION PIPE # 4004559     1)  MIDDLE 4” HANGER CLAMP # 2996

1)  TAIL PIPE # 4005505                                                    

1)  TAIL PIPE EXTENSION # 4005507

1)  MUFFLER #5024-114AL

INSTRUCTIONS FOR KIT #4004555           4” DIESEL KIT TURBO-BACK KIT             

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.

FOR DETAILED DIGITAL PICTURES OF THIS SYSTEM INSTALLED EMAIL US AT:  HEARTTHROB@WILLMAR.COM.