INSTRUCTIONS FOR KIT #4404555
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
#4404555:
1) DOWN PIPE # 4404556
4)
4” STAINLESS STEEL CLAMPS #MC7400SS
1) FRONT EXTENSION PIPE #4404557
1) REAR 4” HANGER CLAMP # 2995SS
1) 16-1/2” MIDDLE EXTENSION PIPE # 4404558 2) FRONT 4” HANGER CLAMP # 2997SS
1) 34” REAR EXTENSION PIPE # 4404559
1) MIDDLE
4” HANGER CLAMP # 2996SS
1) TAIL PIPE # 4405505
1) TAIL PIPE EXTENSION # 4405507
1) MUFFLER #5024-114SS
INSTRUCTIONS FOR KIT #4404555
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
NOTE: THIS KIT
IS MADE OF 409 STAINLESS STEEL. IT MAY
BE BROWNISH IN COLOR, AND A MAGNET WILL STICK TO IT.