INSTALLATION INSTRUCTIONS

1999-2005 FORD 6.0 & 7.3L POWERSTROKE F SERIES

#1. Start by spraying WD40 or a spray lube on the turbo clamp tee bolt, it is on the back side towards the firewall.

#2. Use something like white lithium grease to spray on the rubber grommets which your stock exhaust is attached to, it will help them slip off a little easier.

#3. Cut the stock exhaust in front of the transmission support and behind the muffler. Use a flathead screwdriver to pry the hangers loose from the rubber hanger grommets. Some of the hangers have a heat shield which we also remove.

#4. Remove the turbo clamp, use an 11mm deep well socket on a ¼” or 3/8” drive ratchet, it is hard to get at. You may want to loosen one of the intercooler tubes to get better access. Pry the clamp loose with a large flat head screwdriver.

#1. Slide the turbo downpipe up from the underside of the vehicle, it helps to have someone hold it in place or use a bungee cord. Loosely attach the turbo clamp enough to just hold it in place.

#2. Install the second section of tubing to the outlet of the downpipe, slip the hanger into the grommet at the transmission support and loosely tighten clamp.

#3. Install hangers for muffler, glass pack or muffler eliminator and then drop the muffler in place. If you want less sound install the glass pack or muffler so you can see the openings of the baffles when you look through the inlet end. If you want maximum flow reverse it so you cannot see openings. It will only be slightly louder.

#4. Position front half of tailpipe into outlet end of muffler, check to make sure it is centered over the rear axle. On some models you may trim 4” or so off inlet end to give maximum clearance but measure and check clearance twice and cut once.

#5. Install tailpipe hanger and rear half of tailpipe, if you bought a tip slip it over outlet end of tailpipe and mark it in case you need to trim it a little. Then simply tighten the bolt on tip.

#6. Measure the last section of tubing which will go into the muffler inlet and trim to length if needed, we furnish enough tubing to handle all cab styles and bed lengths.

#7. When the system is all together starting from the downpipe outlet start tightening the clamps and move towards the rear of vehicle. Make sure you have enough clearances at supports, rear shock and spare tire. Lastly tighten the turbo clamp.

We seldom if ever weld the complete system, at most a couple of tack welds at each joint should suffice.