MAGNAFLOW INSTALLATION INSTRUCTIONS FOR 17922/17978 2003-07 FORD F-SERIES

Warning: When working on, under, or around any vehicle exercise caution. Please allow the vehicle's exhaust system to cool before removal, as exhaust system temperatures may cause severe burns. If working without a lift, always consult vehicle manual for correct lifting specifications. Always wear safety glasses and ensure a safe work area. Serious injury or death could occur if safety measures are not followed.

Step 1:

(Carefully read all instructions before installation) Disconnect the vehicles battery before removal of the OEM exhaust. This will allow the computer to reset itself with the new system and prevent electrical accidents. You will temporarily need to remove the passenger's side upper stabilizer bar mount, and loosen the lower mount as shown in
Diagram 2. This will allow the bar to swing out of the way. The next step is to remove the lower mounting bolt of the passenger's side rear shock as shown in Diagram
3 to allow the shock to swing out of the way. Unbolt the rear half of the exhaust system from the catalytic converter, disengage the welded hangers from the rubber insulators, and remove the muffler/tailpipe assembly from the vehicle. Loosen the V-band clamp that fastens the downpipe to the turbo housing, but do not remove it. Once the clamp is loose, slip the V-band clamp off of the downpipe and allow it to rest on the turbo housing. The downpipe and catalytic converter can now be removed from underneath the vehicle.

Step 2:

Begin installation of the new system by fitting the new downpipe into position from under the vehicle. Fasten the downpipe to the turbo housing using the OEM V-band clamp, but leave it loose for final adjustment of the complete system. Fit the lower downpipe into position and fasten it to the upper downpipe using the pre-welded band clamp. You can now reinstall the stabilizer bar. Refer to Ford's shop manual for proper torque specifications of all suspension mounts.

Step 3:

If you are retaining the OEM catalytic converter, use the converter extensions with the supplied 3.50" and 4" clamps and OEM fasteners at the 2-bolt flange. If you are not using the converter, use the downpipe extension and 4x9" extension pipe without the converter extensions. The 18" extension pipe is for CC/LB models, CC/SB models dont need it, and shorter models may require trirning of the 2-bend extension pipe. Once you have determined which extension pipes are needed, install them using the supplied 4.00" clamps as shown. Install the muffler, tailpipe extension, and tailpipe in a similar fashion using the supplied clamps and hanger clamps. The adjustable T-clamp is slotted to adjust the height and alignment of the system.

Step 4:

With all components mounted loosely, adjust the system for overall aesthetics and clearance of frame& bodywork. (MAGNAFLOW recommends at least1/2" of clearance between the exhaust system and any body panels to prevent heat-related body damage orfire.)

Step 5:

Once a final position has been chosen for the new system, evenly tighten all fasteners from front to rear. The band clamps must be VERY tight to properly align the pipes and prevent leaks (Approximately 65ft-lbs). U-bolt clamps should be tightened to approximately 30-35ft-lbs. Inspect all fasteners after 25-50 miles of operation and retighten if necessary.