MAGNAFLOW INSTALLATION INSTRUCTIONS FOR 15942 2000-2003 FORD EXCURSION POWERSTROKE 7.3L

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 safe work area. Serious injury or death could occur if safety measures are not followed.

Step 1:

(Carefully read all instructions before installation) Cut the OEM exhaust system in front of the transmission crossmember. Remove the clamp from the turbo-downpipe connection, but do not discard the clamp as it will be re-used to mount the new system. Remove the system from the vehicle, taking care not to damage the OEM rubber insulators. You may need to cut the extension pipe about 1" in front of the muffler to aid in removal of the OEM system.

Step 2:

Starting at the turbo, install the upper and lower downpipes, using the OEM turbo clamp, and a supplied 3.50" clamp. Leave all fasteners loose for final adjustment of the complete system. Working rearward, install the intermediate pipe by fitting the welded hanger into the OEM rubber insulators and by fastening the intermediate pipe to the lower downpipe using a supplied 3.50" clamp. Install the muffler and tailpipes in the same fashion using the supplied 4.00" clamps and the adjustable "T-Hanger"

Step 3:

With all components mounted loosely, adjust the system for overall aesthetics and clearance of frame & bodywork. (MAGNAFLOW recommends at least 1/2" of clearance between the exhaust system and any body panels to prevent heat-related body damage or fire.)

Step 4:

Once a final position has been chosen for the new system, evenly tighten all fasteners from front to rear. Inspect all fasteners after 25-50 miles of operation and retighten if necessary.