My 4 in. MBRP system is on it's way in and I'm a unsure on the installation. Sure instructions come with the system, but they're no replacement for end-user experience. They also don't mention all the little tips and tricks that fix installation problems and make the installation easier. A buddy and I are installing the system as soon as it gets in and I don't want to break anything or make any costly mistakes. (probably tomorrow early afternoon) Many of you have done this before and have better understanding as to how this should work. What are some tips, tricks, and things I should do/avoid doing in order to make the installation easier on a 2wd X?

 

If you've been following the 5" exhaust thread then you know I will be going final on mine tommorow. Been a one man job and I didn't want to cut the oem exhaust. Let me know if this applies to you. If not you shouldn't need to jack xmission and remove the crossmember. I did need my 13 y/o son to come out and help hold the turbo downpipe from the bottom while i got it lined up with the clamp. The other thing was that I have heard people say on this forum to hit the downpipe clamp with a hammer to loosen it. I did try this with an extra long punch and screwdriver to no avail. I ended up horsing that clamp loose from the bottom by muscling the downpipe around until it broke free. It will. Maybe a combination of both, just don't break anything.
A couple of other things, I sprayed all oem hardware(threads) on the oem exhaust with wd40 and worked those threads ove 2x days before I removed them and they were still a bear. Finally, my kit used oem hangers and recommended spraying the rubber hangers with wd40 to aid in removal/install. I don't like that and used soapy water which works just as well but doesn't deteriorate rubber or remain slippery when installed. Good luck and enjoy. Oh, I also lowered the spare, no sense fighting around that thing esprcially with a 5".

 

To remove the v clamp at the turbo I used an air chissel with a straight punch in it. It doesn't take any pressure. On either side of the clamp just rattle the air chissel against the pipe or turbo and it will come loose. To remove the down pipe you will have to cut it or drop the cross member. Fit all the pipes together under the truck and tighten from the front to the back.

 

Might I add, with the v-clamp, when you think you've loosened it enough to come off, loosen it more. It will seem loose enough but it's only playing with you. I too broke it loose by wiggling the down pipe and a few taps with a cold chisel and hammer. I would say that the v-clamp is the hardest part of the whole thing. I was lucky in that my hangers came out of their grommets rather easily. I used a little motor oil and a small brush about an hour before we did it. If you have help, and with a 4", it'll be easy. Good luck to you.

 

Tenn01PSD350, mech2161, GeoffNJ, believe it or not, the advice that each of your gave me proved extremely useful in at one point or another. If I lived near any of you (and weren't so busy ) I'd get you a couple brews

The system is now installed and although some make it sound easy, it was a bit difficult. My downpipe came off surprisingly easy; it didn't even put up a fight. The only fight was when I had to completely remove it, but the sawzall handled that. The other part was getting the tailpipe over the axle. I had to remove my rear shock as well as avoid breaking the right rear brake line. The middle extension pipe went on easy, but getting the crappy MBRP muffler to go between the pipes was one hell of a job. With the shock still off my buddies helped manuver the extension pipe and the tailpipe so it would all fit. Once I got it together, I started at the downpipe, tightened everything up, and went for a drive. The only thing I didn't like was the way the muffler sounded. It was too damn quiet! (not to mention it sounded terrible, no grunt, not even remotely throaty) No big deal though, I'm going to have my exhaust guy either weld back on my Aeroturbine 4040 (something I KNOW has some cojones) or I may just straight pipe it. All in all, it turned out to be a 3 man operation that took about 3-4 hours from start to finish. I did learn one thing above everything else, I now know why people pay to have these things installed......

 

straight pipe it. you'll LOVE it. i know i did, im not looking back.

 

Tenn01PSD350, mech2161, GeoffNJ, believe it or not, the advice that each of your gave me proved extremely useful in at one point or another. If I lived near any of you (and weren't so busy ) I'd get you a couple brews

We'd never be too busy to help with a Powerstroke...or beer.

I'm glad it went well for you. I'm suprised that a 4" was tough over the axle. My 5" was in 2 pieces; the axle bend, then the tailpipe. Either way. Sorry you did all that work and "los cojones se fue." Hopefully they'll come back with the aero or straightpipe. Let's face it, most of us wouldn't bother with new exhausts if it weren't for the sound.

 

agreed! i will never have a muffler on my psd anyomre