Step #3 Again, with a Sawzall, cut the stock tailpipe off of the stock muffler. Pry the rubber pipe hangers free from the frame mounts. Rotate the tailpipe out of it's confines and off the truck. Remove the rubber hangers and set aside.

Step #4 Remove the rubber pipe hangers from the muffler and pipe hangers at the frame. Lower and remove the stock pipe extension and muffler towards the back of the vehicle. Remove the rubber hangers and set aside. Step #5 Insert the new head pipe from under the vehicle. Attach the pipe and clamp at the turbo outlet. Tighten enough to hold the pipe in place but not firmly. Attach the short pipe extension that is slightly contoured to the head pipe. The contour should be aligned to clear the transmission cross member mounting bolts. Tighten clamps lightly. Do not over tighten as the clamps are strong enough to dimple the pipe wall. Place and loosely tighten the first pipe hanger. Use a rubber hangar set aside in previous steps.

The short pipe extension is contoured to
allow proper clearance at the transmission cross member.

Step #6 Remove the spare tire. Install the new tail pipe and muffler. Hang the muffler and tailpipe via the stock frame mounts and new clamp/mounts using the rubber hangars set aside in previous steps. Determine the distance from the front of the muffler to the rear of the first pipe extension. Remember that you must measure to include overlap at each end of the pipe so that the pipe is long enough to slip over the front pipe extension and into the muffler. To be safe, add an inch or two above that. You can always cut off more for the perfect fit. Cut the pipe with a Sawzall or Cut-off saw. Use the die grinder or a rat tale file to debur the inside of the pipe.

Step #7 Install the long pipe extension with clamps tightened lightly. Support the entire pipe assembly with a floor jacks and, or jackstands. Insure that the pipe, muffler and hangars have adequate clearance in all areas. Rienstall the spare tire. Note: We could not use the standard "rear of tire" tail pipe design due to the design and installation custom suspension components on our truck. We cannot comment on the fit of the tailpipe in this area.

Install the muffler so that the angled holes
in the muffler core catch exhaust pressure.
This view should be seen looking into the
muffler and towards the back of the vehicle.

The modified suspension on our truck required that
we use modified pieces of the tailpipe portion
of the kit to route the exhaust outlet
to a location in front of the rear tire.

Step #8 Once clearance has been achieved in all areas, tighten all clamps (including the clamp at the turbo outlet) and hangar assemblies to snug the fit in each area. Do not tighten completely. You may have to make changes. Wiggle the pipe assembly vigorously to double check clearance. Adjust as needed. Time for a Test Drive!

Step #9 We found that the most critical clearance point occurs at the transmission cross member when our truck is pulling away in gear, off of idle. The torque of the motor would push the pipe against the cross member. All other areas fit perfectly. We corrected this issue with further adjustment of the pipe routing while supported with a floor jack. Completely tighten all hangars, clamps etc.

Test Drive and Performance Results Our performance test drive immediately revealed a significant increase in off idle response and engine performance. The Turbo seemed to spool up faster and initial indications show an slight increase in gas mileage. Initial EGT temps decreased by 100-200 degrees in around town driving. Long pull EGT dropped by 150 degrees. Details are as follows:

We have achieved our EGT temperature goals as well as a significant increase in "off idle" performance. But wait! It gets better. Just after installation we traveled from Las Vegas, NV to Newport Beach, CA. With the cruise control set at 78MPH, we observed a mileage per gallon jump from a commonly observed, previous rate of 13.5 MPG to just under 14.5 MPG. Almost a 1 MPG increase. This is significant for a lifted, 7700lb truck with poor aerodynamics. With this important step in place we are ready for our next set of modifications. Over the next few months we will add Performance Injectors from Diesel Research along with a Chip upgrade from Bully Dog. Our goal is to exceed 400 horsepower at the crankshaft while retaining full driveability. Stay tuned!