INSTRUCTIONS FOR 5” DIESEL KIT TURBO-BACK KIT     #4054555

FITS: 1999-2003 Full-size Ford F250/F350 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 thoroughly before you begin.  We highly recommend the use of a higher flowing air filter or cold air kit, and a power programmer or high performance chip, for use with this exhaust system.  

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.  Note:  there are two bolts on the o.e. exhaust heat shield that we recommend that you cut or trim for clearance of the 5” front extension pipe.  They are near the end of the heat shield before the o.e. muffler.

2)  Install the down pipe to the turbo and install the original v-band clamp.  Tighten only enough to hold in place.  Be sure to rotate this pipe for clearance.

3)  Install the front extension pipe to the down pipe using a 5” clamp, making sure the clamp clears the heat shield.  It is the extension pipe with 3 shallow bends in it, id end is the inlet.  Trim the bolts on the heat shield if you have not done so yet.  install the front 5” hanger clamp (single wire hanger, see drawing) to the front extension pipe at the o.e. mount along side the front extension pipe.  Attach the wire portion of the hanger to the o.e. hanger mount along side the pipe.

4)  Both of the middle (24” w/shallow bend) and rear (34” i.d./o.d.) extension pipes will fit the crew cab long box models (172.4” w.b.) without cutting.  On all other wheel base models, you will need to trim the extension pipes as necessary:

                CREW CAB LONG BOX (172.4”)       BOTH EXT. PIPES NO CUTTING

                CREW CAB SHORT BOX (156.2”)     BOTH EXT. PIPES, TRIM 16” FROM O.D. END OF REAR EXT.

                SUPER CAB LONG BOX (158”)         BOTH EXT. PIPES, TRIM 14.5” FROM O.D. END OF REAR EXT.

                SUPER CAB SHORT BOX (141.8”)    MIDDLE EXT. ONLY, NO CUTTING

                REGULAR CAB (137”)                        MIDDLE EXT. ONLY, TRIM 5” FROM O.D. END OF FRONT EXT.

5)  Use a 5" clamp to attach the i.d. end of the 24” middle extension pipe to the front extension pipe (for regular cab models, cut this pipe to length).

6)  If necessary, attach the 34” rear extension pipe (cut to length if necessary) to the middle extension pipe using a 5” clamp. 

7)  Install the muffler to the extension pipe using the middle 5” hanger clamp.  Attach the wire portion to the o.e. mount beside it.  Note:  the muffler is reversible, and you may need to rotate the muffler for clearance of the frame and drive shaft.

8)  Install the front tail pipe to the muffler using the front tail pipe 5” hanger clamp (two wire hangers on it) at the connecting point of the front tail pipe and muffler.  Install the wire hangers on the hanger clamp to the o.e. rubber mounts above. 

9)  Install the rear tail pipe to the front tail pipe using a 5” clamp.

10)  Install the rear tail pipe 5” 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.

11)  For those without dually models, you will need to cut the tail pipe at the rear to length.  You may need to trim to length and style of cut.

12)  Tighten all clamps and bolts and check for clearance of the frame, body, and brake and fuel lines.

HARDWARE KIT FOR KIT #4054555:

1)  DOWN PIPE # 4054556                                  4)  5” CLAMPS #MC7500

1)  FRONT EXTENSION PIPE # 4054557                         1)  FRONT TAIL PIPE 5” HANGER CLAMP # 2835

1)  24” MIDDLE EXTENSION PIPE # 4054558                1)  FRONT 5” HANGER CLAMP # 2837

1)  34” REAR EXTENSION PIPE # 4054559     1)  MIDDLE 5” HANGER CLAMP # 2836

1)  MUFFLER #7018-115AL                                               1)  REAR TAIL PIPE 5” HANGER CLAMP # 2834                        

1)  FRONT TAIL PIPE # 4055506                                      

1)  REAR TAIL PIPE # 4055507        

5” Turbo Diesel Exhaust Kit

4054555                                                                                              

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.