409S
®
Stainless Steel
SYSTEM #817546
2003-2007 FORD F-SERIES SUPER DUTY
6.0L POWERSTROKE TURBO DIESEL ENGINE
ALL WHEELBASES · **AUTOMATIC TRANS. ONLY**
Removal:
1)
Use a pry bar to separate the stock hangers from the rubber mounts on the vehicle. (A
lubricant of some type will usually make this a little easier.)
2)
Using a hacksaw or sawsall, cut the stock tailpipe off just behind the muffler. Remove the
tailpipe after cutting.
3)
At the bottom of the stock down-pipe there will be a two bolt, flanged connection. Remove the
two nuts and remove the rear portion of the system. This section may or may not include a catalytic
converter. If it does, it will legally need to be reinstalled with the Flowmaster system.
4)
On 2003-2004 models the factory down-pipe from the turbo is wrapped in several sheets of
heat shielding that is secured with 1/4” wide stainless straps. This shielding must be removed in
order to get the down-pipe out. The stainless straps can be cut with a cut off wheel or tin snips.
Once the straps are cut, the layers of shielding can then be worked out one at a time with some effort
(be very careful as this shielding material is sharp).
5)
On 2003-2004 models remove the transmission dipstick and upper section of the tube. There
is a stud with a nut on the right cylinder head that secures the tube. Once this nut is removed, the
dipstick tube can be pulled out and moved out of the way during the installation of the down-pipe.
6)
On 2003-2004 models located at the rear of the left cylinder head there is an engine lifting
plate (black) that must be unbolted and removed in order to get the down-pipe out. It is fastened with
two 6mm Allen head screws. They are difficult to reach, but not impossible.
7)
Cut the stock down-pipe at a point about 18” ahead of the bottom flange. This is necessary to
get the pipe to clear the cross-member during removal.
8)
From the top of the engine, there is a V-band clamp at the rear of the turbo housing that
secures the down-pipe. Use an 11mm deep socket to loosen and remove the single T-bolt/nut on this
clamp. Once this is loose, it may be necessary to “whack” the pipe with a hammer from below in
order to break the clamp connection loose. This will allow the remaining section of down-pipe to be
removed by twisting and working it out down through the bottom side.
