MBRP S5206409 User Manual
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Figure #1
Figure #2
Figure #3
Figure #4
Installation Instructions for System #; S5206409, S5206AL
Removal of stock FORD system:
Loosen the nut on the band clamp located behind the catalytic converter using a 15mm wrench or socket.
See Figure #1
Remove the muffler and tail pipe from the OEM rubber hangers. On 03-04 trucks remove bottom shock bolt
of the passenger side shock to remove the system in one piece. This is not required on 05 models.
Separate the stock exhaust at the slip joint located behind the catalytic converter and remove the muffler and
tail pipe from under the truck. Re-install the bottom shock bolt.
Installation of MBRP Inc. Performance Exhaust
Hang the “T” clamp hanger in the factory rubber insulators located right above where the rear of the factory
muffler was located. Temporarily hang the muffler in place and measure from the front of the muffler to the
short length of factory pipe attached to the rear of the catalytic converter. This will give you the required
length for the extension pipe.
Cut the extension pipe to the required length and attach it to the factory pipe behind the catalytic converter.
See Figure #2
Install the muffler over the extension pipe. The hanger-clamp is used at the connection between the muffler and the
extension pipe and installed into the OEM rubber hanger at this position. Install the “T” hanger-clamp into the two OEM
rubber hangers located above the outlet of the muffler. See Figure #3
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 to complete. See Figure #4
Install provided clamps around pipes where needed. Adjust tail pipe and check along the whole length of
the exhaust system to ensure that there is adequate clearance around the spare tire, fuel and brake lines or
any wiring. If any interference is detected relocate or adjust.
Make sure the exhaust is in place before tightening clamps. Start at the front of the exhaust system and
begin tightening all connections.
Congratulations! You are ready to begin enjoying the improved performance and driving experience of your MBRP Inc. Performance Diesel Exhaust
system. We hope you enjoy your purchase.
S5206 © 6/05
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