9) On 2003-2004 models once the down-pipe is removed, on the right side of the firewall is a
small stud sticking out that fastens the heat shielding blanket to the firewall. This stud needs to be
trimmed down to make the down-pipe installation easier. This can be done using a sawsall or cut-off
wheel.
Installation:
1) From the bottom, fit the upper down-pipe #46043Sup into position on the turbo outlet. Use the
original V-band clamp to secure the pipe to the joint. Snug up the bolt on the clamp, but leave it loose
enough to allow pipe to rotate slightly. You will fully tighten this clamp after the remainder of the
system in installed. Note: On 2005-2007 models it is extra tight placing #46043Sup and into place
and requires a tap with a rubber mallet.
2) Place a provided clamp onto the bottom of pipe #46043S then carefully slide the lower down-
pipe #46044Sover the cross-member from the rear and up into position on the upper down-pipe.
The clearance on this pipe is tight, but final adjustment at the end of installation will provide adequate
clearance. Tighten the clamp enough to hold, but still allow for adjustment.
3) Slip the clamp/hanger #304HA over the lower down-pipe and into the rubber hanger mount on
the frame. Tighten the clamp just enough to hold in position.
4) Install either the original catalytic converter or the adapter pipe #46046Sonto the rear of the
lower down-pipe and install a provided 4” clamp.See Appendix A below for installing OEM converter.
5) Install the intermediate pipe #46045Sonto the cat or adapter pipe. (Based on production
variations, below is a list of cab designs, and wheel bases to cut your intermediate pipe to fit your
application. Double check all measurements before cutting your intermediate pipe.)
Regular Cab – 4x2 or 4x4
Long Bed – 137.0” W.B.- If not using catalytic converter use pipe #46045S behind down pipe.
If there is a catalytic converter use pipe #46046S and trim to desired length.
Super Cab – 4x2 or 4x4
Short Bed – 141.8” W.B. Trim 36.5” off the rear of pipe #46045S
Long Bed – 158.0” W.B. Trim 20.5” off the rear of pipe #46045S
SuperCrew – 4x2 or 4x4
Short Bed – 156.2” W.B. Trim 22.5” off the rear of pipe #46045S
Long Bed – 172.4” W.B. Trim 6.5” off the rear of pipe #46045S
6) Slip hangers #276HA and #277HA over the intermediate pipe and into the rubber hanger
mounts on the frame. (Some models require only one of these hangers.)
7) Slip hanger #429HA over the muffler inlet neck. Install muffler #14020100-Z onto the rear of
the adapter pipe. Slide the inlet hanger into the rubber hanger mount to support the muffler and
tighten just enough to hold in position.
8) Place a provided 4” clamp onto the muffler outlet and then place front section tailpipe #46047S
into position over the axle and into the muffler outlet. Then, connect the two hangers on the pipe to
the rubber mounts on the vehicle. Tighten the clamp just enough to hold in position.
