Pypes Performance Exhaust STD080 - Manual

STD080
2001-2007.5 Chevy 6.6L Off Road 4” Turbo-back - 409SS
Tools needed: 9/16” end wrench or socket, 7/16” deep socket, hacksaw
or sawzall, aerosol lubricant.
(If your vehicle is equipped with a catalytic converter, it is unlawful
to remove.)
Removal of Original System
1) Start under the vehicle. Find the four bolt flange just behind the catalytic converter, loosen and remove the bolts on this
flange. (Your vehicle may have a band clamp in place of the four bolt flange, if so loosen and remove this clamp.)
2) Loosen the “T” bolt on the V band clamp. Gently pry clamp loose and save for re-use.
3) Loosen the bolts holding the hanger bracket to the transmission. Remove the bracket and save for reinstallation.
4) Remove the front pipe by pulling it towards the front of the truck.
5) Re install the bracket on the transmission.
6) Cut the original system just behind the muffler.
7) Spray the stock hangers with lube and pry rubber mounts from the system. Leave the rubber mounts attached to the truck for
re-use.
8) Remove the old system.
Installation of New Performance System
(Hint: Do not fully tighten any clamps until the complete system is installed and aligned.)
1) Install the front pipe using the stock v-clamp and the provided hanger clamp at the transmission bracket.
2) Attach the 12” double bumped adapter to the front pipe using a clamp.
3) Hang the muffler in the stock location using the hanger clamp on the outlet. This determines the placement of the rest of the
system.
4) Install the first tail pipe into the outlet of the muffler using the hanger clamp already installed. Rotate the pipe as needed to
pass next to the shock absorber. This is important in positioning the tail pipe.
5) Install the second tail pipe on to the outlet of the first tail pipe with a clamp. Rotate as needed to level the outlet behind the
rear tire. Attach the hanger clamp in the stock rubber.
6) Install the cross member pipe into the adapter placing the bend around the cross member. The pipe does not require cutting to
fit Crew Cab trucks. For extended cab trucks, approximately 9” needs to be cut off the end with the longest straight section of
pipe. (Installation check: measure from the muffler to the adapter and add 2.5” to verify the length required).
7) Long beds will need to use a straight pipe extension between the cross member pipe and the muffler. Depending on muffler
choice this pipe may very between 15” and 24” in length and will need to be trimmed to length by installer. When using a
muffler shorter than 30” the straight pipe extension may need to be used on short beds also.
8) Attach the final piping into the muffler with a clamp.
9) Starting at the front pipe, align and tighten all the pipes and clamps. Start the engine and check for leaks.
**Disclaimer**
This performance exhaust system was not designed to the specifications of a dual rear wheel application; additional components may
be necessary for the proper installation and fit.
Pypes Performance Exhaust
2880 Bergey Road Unit O Hatfield, PA 19440
800-421-3890 (voice) 215-712-9968 (fax)
www.pypesexhaust.com