MBRP S6240 - Manual (Page 2)

Removal of Stock System:
1. Apply a penetrating lubricant liberally to all exhaust fasteners, hangers and rubber insulators.
2. Loosen the nut on the band clamp located behind the catalytic converter using a 15mm wrench or
socket.
3. Remove the muffler and tail pipe from the OEM rubber hangers. Cut the stock exhaust behind the muffler
and remove the tail pipe. Separate the slip joint located behind the catalytic converter and remove the
remaining section of the stock exhaust.
4. Remove the catalytic converter by removing the two nuts holding the inlet flange together using a 15mm
wrench or socket.
5. Remove the down pipe from the turbo by removing the band clamp using an 11mm socket. Retain the
band clamp for the installation of the new down pipe. Cut the down pipe in front of the transmission cross
member to remove.
(Note: The stock down pipe can be removed in one piece by removing the transmission cross member.
MBRP Inc. recommends that this procedure only be done by qualified, trained professionals using tools
and equipment designed to safely carry out this process.)
Installation of MBRP Inc. Performance Exhaust:
1. Install the Down Pipe in the same position as the stock down pipe and attach the flared end to the turbo
using the stock band clamp. Do not fully tighten until all components are in place.
2. Attach the Mid Pipe to the Down Pipe using the 3 ½" Clamp to secure the slip joint.
3. Install Extension Pipe #1 over the Mid Pipe. Extension Pipe #1 is pre-cut for 165” wheelbase vehicles
and will require trimming for the 141” wheelbase vehicles. For the 201” and 189” wheelbase vehicles
install Extension Pipe #2 over Extension Pipe #1. For 189” wheelbase vehicles Extension Pipe #2 will
require trimming.
Installation Tip: Temporarily install the Muffler and the Tail Pipe using the factory rubber insulators and
the “T” Hanger Clamp. Measure from the Muffler to the Mid Pipe and cut the Extension Pipe to the
required length.
4. Install the Muffler over the Extension Pipe. Install the “T” Hanger Clamp
into the two OEM rubber hangers located above the outlet of the Muffler.
Refer to the illustration on the right for the proper direction of air flow
through the Muffler.
5. Install the Tail Pipe from the rear of the truck, over the axle and attach to
the Muffler Outlet. Install the tail pipe hanger into the OEM hanger, adjust
for best axle clearance and Tail Pipe exit location to complete.
6. Install the provided clamps around the pipes where needed. Adjust the Tail Pipe and check along the
whole length of the exhaust system to ensure that there is adequate clearance around the fuel and brake
lines or any wiring. If any interference is detected relocate or adjust.
7. Make sure the exhaust is in place before tightening the clamps. Start at the front of the exhaust system
and begin tightening all connections.
S6240 © 05/08
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