INSTRUCTIONS FOR KIT #4004570           4” DIESEL KIT CAT-BACK KIT   

FITS: 2003-2004 FULL-SIZE FORD 3/4 & 1 TON F SERIES W/6.0L POWERSTROKE TURBO DIESEL, 2WD & 4WD, ALL WHEEL BASES (137”-172.4”), THIS IS A CAT-BACK EXHAUST KIT, FOR VEHICLES WITH CATALYTIC CONVERTER. 

NOTE:  DO NOT TIGHTEN ANY CLAMPS OR BOLTS UNTIL THE LAST STEP!  READ THESE INSTRUCTIONS FULLY AND THOROUGHLY BEFORE YOU BEGIN.  BEFORE DOING ANY CUTTING, VERIFY THAT THE LENGTH TO CUT OFF IS CORRECT.

NOTE:  DUE TO THE EXTREME DIFFICULTY OF REMOVING, MODIFYING, AND INSTALLING THE DOWN PIPE, IT IS NOT INCLUDED IN THIS EXHAUST SYSTEM.  THE DOWN PIPE KIT MAY BE ORDERED THROUGH J.C. WHITNEY SPECIAL ORDERS DEPARTMENT, PART NUMBER IS #4004571.  WE RECOMMEND THIS DOWN PIPE ONLY FOR VERY ADVANCED AND PATIENT INSTALLERS.   YOU MAY NEED TO CUT YOUR O.E. DOWN PIPE IN NUMEROUS PIECES TO REMOVE IT.  THE CONVERTER AND DOWN PIPE ARE NOT INCLUDED IN THIS KIT.

1)  REMOVE THE EXHAUST SYSTEM AFTER THE CONVERTER.  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. 

2)  THE EXTENSION PIPE (47” STRAIGHT PIPE SHRUNK TO 3-1/2”) WILL FIT THE CREW CAB LONG BOX MODELS (172.4” WHEEL BASE).  ON THE SHORTER WHEEL BASE MODELS, YOU WILL NEED THE EXTENSION PIPE TO LENGTH, FROM THE 4” O.D. END, THE END THAT IS NOT SHRUNK:

                CREW CAB LONG BOX (172.4”)       EXTENSION PIPE LENGTH = 47”                     NO CUTTING

                CREW CAB SHORT BOX (156.2”)     EXTENSION PIPE LENGTH = 30.8”                  CUT OFF 16.2”

                SUPER CAB LONG BOX (158”)         EXTENSION PIPE LENGTH = 32.6”                  CUT OFF 14.4”

                SUPER CAB SHORT BOX (141.8”)    EXTENSION PIPE LENGTH = 16.4”                  CUT OFF 30.6”

                REGULAR CAB LONG BOX (137”)  EXTENSION PIPE LENGTH = 11.6”                  CUT OFF 35.4”

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

4)  INSTALL THE FRONT 4” HANGER CLAMP TO THE EXTENSION PIPE, AND ATTACH THE WIRE PORTION TO THE O.E. HANGER ALONG SIDE THE PIPE.

5)  INSTALL THE MUFFLER TO THE EXTENSION PIPE USING THE MIDDLE 4” HANGER CLAMP (TWO WIRE HANGERS ON THIS HANGER CLAMP).  NOTE:  THE EXHAUST SHOULD FLOW OVER, AND NOT DIRECTLY INTO, THE LOUVERS OF THE MUFFLER.

6)  INSTALL THE TAIL PIPE TO THE MUFFLER USING THE MIDDLE 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. 

7)  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.

8)  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.

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

HARDWARE KIT FOR KIT #4004570:                                                                                 

1)  TAIL PIPE EXTENSION # 4005507                             1)  FRONT 4” HANGER CLAMP # 2997

1)  FRONT EXTENSION PIPE # 4004573                         1)  MIDDLE 4” HANGER CLAMP # 2996

1)  TAIL PIPE # 4005505                                                     2)  4” CLAMPS #MC7400

1)  MUFFLER #5024-114AL                                               1)  REAR 4” HANGER CLAMP # 2995

                                                                `                               1)  3-1/2” CLAMP #MC7312

INSTRUCTIONS FOR KIT #4004570           4” DIESEL KIT CAT-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.