I recently installed a Flowmaster 4 inch cat
back exhaust with a Hushpower muffler.
Its a pretty easy straight forward process. You only need a few tools. Metric and standard impact sockets and an air impact. A chain wrench, sawzall, or metal cutting chopsaw if you have one, and WD40 or PB blaster.
First thing you want to do is spray the exhaust hangers down with the WD40 so the slide out of the factory rubber isolaters easily. Dont damage the rubber mounts as you need them to install the new exhaust. You also want to give all the exhaust clamps a squirt so that they break loose nice and easy.
Then you start by removing the old exhaust. I recommend having a helper around for the whole process. The muffler is heavy
Start by crawling under the truck near the rear axle. With your sawzall. Cut through the factory exhaust at the bend right above the rear axle. Then remove that piece leaving the rubber isolater on the hanger in place.
Next loosen up all the exhaust clamps all the way up to the catalytic coverter. You may want to spray all the slip joints doing with penetrating oil prior to doing this it makes them slip a bit easier.
The next step is to remove the muffler. Have a helper around for this. Its quite heavy.
Once you have that done remove the remaining pipe all the way up to the Cat
or delete pipe if you have one.
Once you get that done you are ready to install the new Cat
The first step is to slide the 3.5 inch to 4 inch pipe adapter on to the Cat
or delete pipe whichever you may have. This pipe is notched to align with the nipple on the factory pipe.
I recommend spraying the joints on all the pipe with WD40 or whatever lube you prefer for assembly. The joints will slip together alot easier that way.
There are several different exhaust clamps included with this kit. With various hangers.
Depending on your trucks cab and bed configuration you may not use all of the clamps.
Once you have the adapter pipe in place the next step is to cut the intermediate pipe down to the size indicated in the instructions included with the kit. I used a metal cutting chopsaw to do it. For my supercab shortbed the instructions stated to cut 36.5 inches off the pipe.
When the cut is made. Make sure and either grind or file any burs off the pipe so they slide together nice and easy. Using the hanger clamps provided attach and hang the intermediate pipe. You can use the chain wrench to adjust the pipe to the proper position.
The next step is to hang and place the Hushpower muffler included in the kit. I recommend having a helper around for this. Its not the lightest thing in the world.
Again you can use the chain wrench to adjust the pipe as necessary for clearance and fit.
Once you have the muffler hung the next step is to hang the over axle pipe and adjust it as necessary. I had to twist mine to one side a bit due to the B&W gooseneck hitch in my truck.
After thats done hang and adjust the tailpipe.
Once you have everything hung go back through and check everything over for clearances and go ahead and take your impact and tighten up all the clamps.
Once you are this far head over to the fridge and grab your beverage of choice. You've earned it.
Start the truck listen for any vibrations or anything of the sort and make adjustments if you have to.
After that enjoy the new system. Take the truck for a drive and enjoy the sound.
To see if they have an exhaust system for you, check out this page on the Flowmaster website: Flowmaster Inc.