INSTRUCTIONS FOR KIT #4054575           5” DIESEL KIT TURBO-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 TURBO-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.  YOU WILL NEED TO RE-USE THE FACTORY CATALYTIC CONVERTER.  TO ACCOMMODATE THIS SYSTEM, THE SPARE TIRE WILL NEED TO BE PULLED PERMANANTLY.

1)  REMOVE THE EXHAUST SYSTEM FROM THE VEHICLE, INCLUDING THE DOWN PIPE, EXTENSION PIPE, CONVERTER, MUFFLER, AND TAIL PIPE.  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.  WHEN REMOVING THE DOWN PIPE, YOU MAY NEED TO CUT IT FOR REMOVAL. 

2)  INSTALL THE FRONT PORTION OF THE DOWN PIPE TO THE TURBO, REUSING THE O.E. V-BAND CLAMP. 

3)  INSTALL THE REAR PORTION OF THE DOWN PIPE TO THE FRONT PORTION OF THE DOWN PIPE, USING A 4” CLAMP. 

4)  INSTALL THE O.E. CATALYTIC CONVERTER TO THE REAR PORTION OF THE DOWN PIPE, REUSING THE O.E. BOLTS AND NUTS TO CONNECT THE FLANGES.

5)  INSTALL THE 3-1/2” I.D. END OF THE REDUCER PIPE TO THE CATALYTIC CONVERTER PIPE USING A 3-1/2” CLAMP.

6)  THE EXTENSION PIPE (37-1/4” LONG X 5” ID/OD) 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 = 37.25”                                NO CUTTING

                CREW CAB SHORT BOX (156.2”)     EXTENSION PIPE LENGTH = 21”                     CUT OFF 16.2”

                SUPER CAB LONG BOX (158”)         EXTENSION PIPE LENGTH = 23”                     CUT OFF 14.4”

                SUPER CAB SHORT BOX (141.8”)    EXTENSION PIPE LENGTH = 6.75”                  CUT OFF 30.6”

                REGULAR CAB LONG BOX (137”)  NOT REQUIRED

7)  USE A 5" CLAMP TO ATTACH THE EXTENSION PIPE TO THE REDUCER PIPE.

8)  INSTALL THE FRONT 5” HANGER CLAMP TO THE EXTENSION PIPE, AND ATTACH THE WIRE PORTION TO THE O.E. HANGER ALONG SIDE THE PIPE.

9)  INSTALL THE MUFFLER TO THE EXTENSION PIPE USING A 5” CLAMP, THE MUFFLER IS REVERSIBLE, IT WILL NEED TO BE INSTALLED IN A COCKED POSITION FOR CLEARANCE OF THE DRIVE SHAFT.

10)  INSTALL THE FRONT TAIL PIPE TO THE MUFFLER USING A 5” CLAMP.  INSTALL THE MIDDLE 5” HANGER CLAMP (TWO WIRE HANGERS ON IT) JUST AFTER 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. 

11)  INSTALL THE REAR TAIL PIPE TO THE FRONT TAIL PIPE USING A 5” CLAMP.  INSTALL THE 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.

12)  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.

13)  TIGHTEN ALL CLAMPS AND BOLTS, THE V-BAND CLAMP AT THE TURBO, AND CHECK FOR CLEARANCE OF THE FRAME, BODY, AND BRAKE AND FUEL LINES. 

HARDWARE KIT FOR KIT #4054575:                                                                                                        

1)  FRONT EXTENSION PIPE #                                       1)  MIDDLE 5” HANGER CLAMP # 2823

1)  REAR TAIL PIPE #                                                        1)  FRONT 5” HANGER CLAMP # 2824

1)  FRONT TAIL PIPE #                                                      1)  4” CLAMP #MC7400

1)  MUFFLER                                                                        1)  REAR 5” HANGER CLAMP #

1)  #4004576 FRONT DOWN PIPE    `               1)  3-1/2” CLAMP #MC7312

1)  #4004576 REAR DOWN PIPE                                       4)  5” CLAMPS

1)  REDUCER ADAPTER #

INSTRUCTIONS FOR KIT #4054575           5” 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.