Part # 1008060 w/stainless steel angle cut tips
Part # 1008070 w/painted blunt cut tips
Kit fits ‘02-’03 full-size GM « ton Avalanche, Suburban, Yukon XL, 2WD
& 4WD, w/4.8L & 5.3L V8 motor only and 2-3/4” flanged
exhaust at the converter. Will fit vehicles with factory trailer
hitches. This kit will not fit 6.0L and 8.1L models.
Note: for detailed installation pictures email us at
heartthrob@willmar.com
Heartthrob exhaust systems are manufactured
in--Litchfield, MN
DANGER WARNING: Should the purchaser decide to install this
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.
HARDWARE KIT:
1) 3/8” nut
1) 3” hanger clamp-# 2879
1) fender washer
1) 3/8” lock washer
1) cable tie
1) 3” clamp
8) 2-1/4” clamps
1) swinger hanger #2877
1) 3/8” x 1-1/4” bolts
1) formed flange-#2876
1) front 2-1/4” hanger clamp-# 2878
1) rear 2-1/4” hanger clamp-# 2907
2) muffler tips--stainless or painted
1) right front tail pipe
1) 3” front extension pipe
1) y-pipe
1) left front tail pipe
1) left rear tail pipe
1) right rear tail pipe extension
INSTRUCTIONS:
NOTE: do not tighten any clamps or nuts and bolts until the last
step!! Before cutting any pipes it is a good idea to lay out all
the included pipes along side the vehicle and get a good idea of how
the pipes will hang on the vehicle. Please read the instructions
fully and thoroughly before you begin.
1) Remove the old exhaust system, leaving only the y-pipe, the
converter, and the O.E. rubber hanger mounts on the truck. You
will need to reuse the nuts off the flange at the converter. You
may need to use a lubricant to remove the O.E. hangers on the vehicle.
2) Slide the flat side of the formed flange first over the 3”
front extension pipe. Install the flange and 3” front extension
pipe to the converter flange. Rotate the 3” front extension pipe
for clearance of the cross-member. The offset of the bend should
move the front extension pipe towards the drive shaft (see drawing).
3) Install the y-pipe to the 3” extension pipe (the leg with the
bend goes towards the drive shaft), using a 3” clamp to connect the two
pieces. Locate the original hanger mount located along side the
3” front extension pipe. Install the 3” hanger clamp to the o.e.
hanger along side the pipe and connect the clamp portion to the 3”
front extension pipe.
4) Install the right front tail pipe (it has 4 bends) to the
y-pipe using a 2-1/4” clamp. Make sure that you have at least
1/2” of clearance from the shock. (There is a wire support hanger
for the emergency brake just in front of the rear-most O.E. exhaust
hanger. Bend it forward slightly for clearance of the right front
tail pipe). Install the right rear tail pipe extension (no bends,
I.D./O.D.) to the right front tail pipe using a 2-1/4” clamp. Use
the rear 2-1/4” hanger clamp for the right tail pipe (see drawing) to
connect the right front tail pipe to the O.E. mount above the last bend
in the front right tail pipe. NOTE: you may want to trim
the right (and later the left) tail pipe to your desired length.
5) Install the muffler tip onto the right tail pipe. Use a
2-1/4” clamp to secure the tip to the right rear tail pipe.
6) Install the left front tail pipe (5 bends, short), making sure
that you have clearance between the rear brake line, shock, and spare
tire. You will need to tie off the breather line and brake line
using the included cable tie.
7) Install the left rear tail pipe (3 bends) to the left front
tail pipe using a 2-1/4” clamp. The left tail pipe is routed
between the shock and the frame. Again, you may want to trim the
pipe to length.
8) Install the front 2-1/4” hanger clamp (see drawing) to the
left front tail pipe just after the first bend. You will need to
connect the wire portion of the hanger to the O.E. mount above the
pipe. You will need to rotate the rubber portion of the O.E.
hanger forward and parallel to the ground, and push the assembled
hanger clamp when connected as far forward as possible to make the
connection tight.
9) Locate the mounting hole on the left side after the rear
axle. Install a BR91930 swinger hanger #2877 to the frame using
the included 3/8” x 1-1/4” bolt, nut, lock and fender washer. Use
a 2-1/4” clamp to connect the hanger and the left rear tail pipe.
The bolt should go through the 3rd hole from the bottom, and the strap
portion of the hanger should be mounted parallel with the frame and
ground, and the portion that swings will need to swivel down towards
the pipe (see drawing).
10) Mount the other muffler tip to the left tail pipe using a
2-1/4” clamp.
11) Tighten all clamps, nuts, and bolts. Check for leaks
and for clearance of all brake and fuel lines, and for clearance of all
chassis and frame components. We recommend tack welding the
joints (not necessary though).
