Exhaust install
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Senior User
Joined: Apr 2004
Posts: 241
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From: Seattle
Exhaust install
I have been looking at my exhaust system, planning for the install of the new exhaust I purchased on the group buy, and I can see I am in for a weekend’s work just getting the old downpipe out and the 3.5 new one in. How in the heck do you get it in there?!
From the looks of things I will have to tear out the thermo insulation, then saw off the body seam for 3 or 4 inches. Is this how to do it? Does anyone have any step by steps with photos? If so I think this will pretty useful to all who purchased on the group exhaust buy.
From the looks of things I will have to tear out the thermo insulation, then saw off the body seam for 3 or 4 inches. Is this how to do it? Does anyone have any step by steps with photos? If so I think this will pretty useful to all who purchased on the group exhaust buy.
Postmaster
Joined: Jan 2004
Posts: 4,758
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From: colorado
you will have to saw off the old down(at least i did on my '01). if i remember wright you cut the old one right at the turn from where it comes down and starts to go back. after that it should all come out pretty easy. the new down pipe should be made to just slide right up there. the install is not that bad i did mine in a afternoon on my garage floor... hope that helps
Senior User
Joined: Sep 2003
Posts: 360
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From: Lexington, Ky.
wlihntr, is right you will cut the old one out.
A friend and i did his in about 2 hrs. and there are some photos on this site somewhere, i cant remember right off the top of my head.
Like i said though it was very simple.
Good luck
A friend and i did his in about 2 hrs. and there are some photos on this site somewhere, i cant remember right off the top of my head.
Like i said though it was very simple.
Good luck
Senior User
Joined: Nov 2003
Posts: 331
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From: Abilene TX
If i read your signature correctly you have a 97 model and the install is a little trickier than the new style, I would suggest dropping an E-mail to Quadzilla. He knows more about the 97 and down then anyone else i've seen on this site. To agree with the rest of you and to answer questions reguarding the later models, yes it is quite simple to change the DP out to a 3.5 or 4 inch.. Good luck.
Smokin'
Joined: Nov 2003
Posts: 539
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From: Aston
you're right that you will have to cut the firewall seam, but you will probably also need to bend the firewall back a little to make room for it. use a 3 foot long or so 2x4 and pry against the back of the block (be careful not to pry against the fuel line fitting on the head... i found that one out the hard way 
..) you might be one of the lucky few to have your cab mounted as far back as it can and the motor as far forward as it can in the mounts which would make the install a little easier, if not a bunch of cutting and bending is probably what you will need to do... i had to do a lot more bending and cutting to get the 4" dp in my '96, but it took me less than a day and yours shouldn't be as difficult... just have a few on ice to be ready 
..) you might be one of the lucky few to have your cab mounted as far back as it can and the motor as far forward as it can in the mounts which would make the install a little easier, if not a bunch of cutting and bending is probably what you will need to do... i had to do a lot more bending and cutting to get the 4" dp in my '96, but it took me less than a day and yours shouldn't be as difficult... just have a few on ice to be ready
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Joined: Sep 2003
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From: Lexington, Ky.
Your new DP should be 2 pieces, making the 3.5" install quick and easy.
The old one is the only cutting you should have to do, when you get up to a 4" DP you will have to do some firewall modifacation.
I have a 97 HD and thats what i ve learned.
The old one is the only cutting you should have to do, when you get up to a 4" DP you will have to do some firewall modifacation.
I have a 97 HD and thats what i ve learned.
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Joined: Apr 2004
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From: Seattle
Thanks, guys, I kinda thought that it might be a bit of a job. Does anyone know for sure if it is a two-piece downpipe? Ken, can you tell me?
The other thing I was thinking of doing is wrapping the DP in thermo-tape – does that sound like a good plan?
The other thing I was thinking of doing is wrapping the DP in thermo-tape – does that sound like a good plan?
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Smokin'
Joined: Nov 2003
Posts: 539
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From: Aston
Byrddog, fyi.. going up to the 4" dp is not a simple bolt on for the pre-'99s, it requires an adapter to fit the dp to the turbo, ehich involves eliminating the ebpv., then there is a bunch of modding to do to the firewall.
Craze, I would say wrap it up anyway... i should have wrapped mine up cause it gets a little warmer in the cab around the passenger's feet, and the tranny seems to be running a little hotter....
just my $0.02 and hope that helps
Craze, I would say wrap it up anyway... i should have wrapped mine up cause it gets a little warmer in the cab around the passenger's feet, and the tranny seems to be running a little hotter....
just my $0.02 and hope that helps
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Joined: Sep 2003
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From: Lexington, Ky.
96P
If you read my reply correctly, thats what i said.
I have done this before, and CRAZE said he got a 3.5 DP.
I could be wrong and if i am, sorry CRAZE for leading you in the wrong direction.
Also, the kits i installed came from Motorhaven. Black Diamond, which are the same as the group buy, if memory serves me correctly
If you read my reply correctly, thats what i said.
I have done this before, and CRAZE said he got a 3.5 DP.
I could be wrong and if i am, sorry CRAZE for leading you in the wrong direction.
Also, the kits i installed came from Motorhaven. Black Diamond, which are the same as the group buy, if memory serves me correctly