INSTRUCTIONS FOR # 1024560
FITS 2004 FULL SIZE FORD PICKUP WITH 5.4L V8, 2wd & 4wd, ALL WHEEL BASES.
NOTE:    DO NOT TIGHTEN ANY CLAMPS UNTIL THE LAST STEP!

1)    REMOVE THE SPARE TIRE FROM UNDER THE TRUCK.  BECAUSE OF CLEARANCE
PROBLEMS, YOU WILL NOT BE ABLE TO RUN THIS SYSTEM WITH THE SPARE TIRE IN
ITS ORIGINAL POSITION.  THEREFORE, IT MUST BE PULLED PERMANENTLY!!!

2)    REMOVE EXHAUST SYSTEM LEAVING ONLY THE ORIGINAL Y PIPE, CATALYTIC CONVERTERS, AND O.E. RUBBER HANGER MOUNTS ON THE TRUCK.  

3)  NOTE:  THE EXTENSION PIPES WILL FIT THE LONGER 163” WHEEL BASE TRUCKS WITHOUT CUTTING.  ON ALL OTHER VEHICLES THE EXTENSION PIPES WILL NEED TO BE CUT FROM THE 3" O.D. END (THE END THAT IS NOT SHRUNK OR EXPANDED) AS NECESSARY.  

REG. CAB 6-1/2’ BOX        = 126”        FRONT EXT. ONLY, TRIM TO 24.5” OAL
REG. CAB 8’ BOX        = 144.5”        BOTH EXT., CUT OFF 18.5” FROM MID EXT., 8.5” OAL
SUPER CAB 5’ BOX        = 132.5”        FRONT EXT. ONLY, TRIM TO 31” OAL
SUPER CAB 6-1/2’ BOX        = 144.5”        BOTH EXT., CUT OFF 18.5” FROM MID EXT., 8.5” OAL
SUPER CAB 8’ BOX        = 163”        USE BOTH EXTENSIONS, NO CUTTING
SUPER CREW 5-1/2’ BOX    = 138.5”        USE FULL LENGTH 3” FRONT EXTENSION ONLY

4)    USE A 2-1/2" CLAMP TO ATTACH THE CUT TO LENGTH (SEE STEP 3) 3” FRONT EXTENSION PIPE TO THE CATALYTIC CONVERTER PIPE.  IF NECESSARY, ATTACH THE CUT TO LENGTH (SEE STEP 3) 3” MIDDLE EXTENSION PIPE TO THE 3” FRONT EXTENSION PIPE USING A 3” CLAMP.

5)    USE A 3" CLAMP TO ATTACH THE MUFFLER (#6842 OR EQUIVALENT) TO THE EXTENSION PIPE.  INSTALL THE FRONT HANGER CLAMP TO AN EXTENSION PIPE AT WHERE THE O.E. RUBBER HANGER MOUNT IS ALONG SIDE OF IT.  ATTACH THE WIRE PORTION OF THE HANGER TO THE MOUNT.

6)    INSTALL THE LEFT TAIL PIPE TO THE MUFFLER USING A 3” CLAMP, IT HAS 5 BENDS.

7)    INSTALL THE MIDDLE HANGER CLAMP TO THE LEFT TAIL PIPE JUST AFTER THE FIRST BEND IN THE PIPE.  INSTALL THE WIRE PORTION OF THE HANGER TO THE O.E. RUBBER HANGER MOUNT ABOVE.  BEFORE THE LAST BEND IN THE PIPE, THERE IS A HOLE IN THE FRAME.  YOU WILL NEED TO INSTALL A BR91930 HANGER (IT SHOULD BE BENT TO MOUNT PERPENDICULAR TO THE FRAME) AT THIS HOLE, USING THE INCLUDED HARDWARE.  USE A 3” CLAMP TO CONNECT THE HANGER AND THE LEFT TAIL PIPE.

8)  INSTALL A 25" LONG 3" I.D./O.D. TAIL PIPE EXTENSION TO THE LEFT TAIL PIPE USING A 3” CLAMP.

9)  INSTALL THE RIGHT TAIL PIPE TO THE MUFFLER USING A 3” CLAMP, IT HAS 5 BENDS.

10)  INSTALL THE REAR HANGER CLAMP TO THE RIGHT TAIL PIPE AT THE REAR O.E. RUBBER HANGER MOUNT, CONNECT THE WIRE PORTION TO THE MOUNT.     

11)  INSTALL A 25" LONG 3" I.D./O.D. TAIL PIPE EXTENSION TO THE RIGHT TAIL PIPE USING A 3” CLAMP.

12)    TIGHTEN ALL CLAMPS AND NUTS AND BOLTS AND CHECK FOR CLEARANCE OF BRAKE AND FUEL LINES AND FRAME AND CHASSIS COMPONENTS.

HARDWARE FOR #1024560
1)  2-1/2" CLAMP                                                1)  FRONT EXTENSION PIPE #1024560-1
7)  3" CLAMPS                                                    1)  LEFT TAIL PIPE #1024560-2
1)  (360 SWINGER) HANGER #BR91930        1)  RIGHT TAIL PIPE #1024560-3
1)  5/16" X 1" BOLT                                            1)  6842 MUFFLER
1)  5/16" NUT                                                    2)  TAIL PIPE EXTENSIONS # 1025500-5
1)  5/16" LOCK WASHER1                                1)  MIDDLE EXTENSION PIPE 27” ID/OD # 1024560-4
1)  FENDER WASHER
1)  FRONT HANGER CLAMP-#2861
1)  MIDDLE HANGER CLAMP-#2858
1)  REAR HANGER CLAMP-#2856


1024560

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  IT’S 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, THE 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.
    CALIFORNIA VEHICLE CODE SECTION 27156 PROHIBITS THE ADVERTISING, OFFERING FOR SALE, OR INSTALLATION OF ANY DEVICE WHICH MODIFIES A VEHICLE’S EMISSION CONTROL SYSTEM.  THIS PRODUCT IS  THEREFORE NOT LEGAL FOR SALE OR USE IN CALIFORNIA ON VEHICLES EQUIPPED WITH CATALYTIC CONVERTERS