KIT #8141520
1966-1977 FORD BRONCO 4WD 302
NOTE:  THE CATALYTIC CONVERTERS ARE NOT SUPPLIED WITH THIS EXHAUST SYSTEM.  MUFFLERS AND SOME CLAMPS ARE NOT SUPPLIED WITH SYSTEM.  THIS KIT HAS BEEN DESIGNED FOR USE WITH TURBO MUFFLERS OR AN EQUIVALENT 2-1/4” SINGLE OFFSET MUFFLER.  GLASS PACKS MAY BE USED WITH SOME MODIFICATIONS.

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.  

HARDWARE KIT:            
2)  LB4 HANGERS                    
2)  SNAPPER GROMMETS                
4)  5/16” X 1-1/4” LAG SCREWS            
2)  5/16” NUTS                   
2)  5/16” X 1-1/2” BOLTS                 
4)  2-1/4” CLAMPS                   
2)  BR1 BRACKETS--(BR755)
2)  FENDER WASHERS
2)  2” CLAMPS
2)  THU400 HANGERS--(BR104)    
1)  #627L LEFT MANIFOLD PIPE
1)  #627R RIGHT MANIFOLD PIPE
1)  #16527 RIGHT EXTENSION
1)  #16526 LEFT EXTENSION              
1)  #15508 LEFT TAIL PIPE 
1)  #15509 RIGHT TAIL PIPE
               
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, 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.

INSTALLATION INSTRUCTIONS:

NOTE:  DO NOT TIGHTEN ANY CLAMPS OR NUTS UNTIL THE LAST STEP!!

1)  REMOVE THE OLD EXHAUST SYSTEM.  SAVE THE OLD GASKETS AND FLANGES FROM THE ORIGINAL FRONT PIPE.  

2)  INSTALL THE LEFT (#627L) AND RIGHT (#627R) MANIFOLD PIPES USING THE ORIGINAL GASKETS AND FLANGES.  YOU WILL NEED TO USE YOUR ORIGINAL MANIFOLD STUDS AND NUTS.  TIGHTEN ONLY ENOUGH TO HOLD IN PLACE.

3)  INSTALL THE LEFT (#15626) AND RIGHT (#15627) FRONT EXTENSION PIPES TO THE MANIFOLD PIPES USING 2” CLAMPS.  CLAMP LIGHTLY INTO PLACE.  NOTE:  FOR VEHICLES REQUIRING CATALYTIC CONVERTERS TO MEET EPA GUIDELINES, CONVERTER PART # 73-7774 OR EQUIVALENT SHOULD BE INSTALLED ON PIPES #16527 & #16526.  SEE DRAWING.  CONVERTERS ARE NOT INCLUDED IN THIS KIT.

4)  INSTALL THE MUFFLERS (SINGLE OFFSET, NOT INCLUDED IN THIS KIT) ONTO THE FRONT EXTENSION PIPES USING 2-1/4” CLAMPS.  ROTATE THE MUFFLERS FOR CLEARANCE FROM THE DRIVE SHAFT AND FRAME.  NOTE:  THIS SYSTEM WAS DESIGNED TO USE THE ORIGINAL HANGERS.  ADDITIONAL HANGERS HAVE BEEN INCLUDED FOR YOU TO USE AS NECESSARY.  USE THE STOCK HANGERS OR THE BRACKETS AND LB4 METAL HANGER ASSEMBLY WITH GROMMET TO HANG THE MUFFLERS.

5)  INSTALL THE LEFT (#15508) AND RIGHT (#15509) TAIL PIPES TO THE MUFFLERS USING 2-1/4” CLAMPS.  

6)  MOUNT THE REMAINING HANGERS AND HARDWARE TO THE FRAME NEAR WHERE THE TAIL PIPES CROSS UNDER THE FRAME ON THE WAY OUT TOWARDS THE REAR.   DRILL A HOLE AND BOLT A THU400 RUBBER STRAP HANGER TO THE FRAME AND CLAMP THE TAIL PIPES TO THE HANGERS USING 2-1/4” CLAMPS.  

7)  MAKE SURE THAT ALL THE PARTS OF THE SYSTEM ARE CLEAR OF FRAME MEMBERS, ALL HOSES, SUSPENSION, AND BRAKE AND FUEL LINES.  STARTING AT THE EXHAUST MANIFOLDS, TIGHTEN ALL CONNECTIONS AND NUTS.  MAKE SURE ALL PARTS ARE CLEAR AND WILL NOT LEAK OR RATTLE.  AFTER SEVERAL DAYS OF DRIVING RETIGHTEN ALL BOLTS.