Please read these instructions completely before you start the installation. Familiarizing yourself with all the components mentioned will make the installation much easier.

POWERSTROKE
(`94-'97 7.3L D.I.)
TURBO DOWNPIPE
INSTALLATION

Raise the vehicle to working height with hoist or jack stands.

Remove the two nuts at the catalytic converter and turbo downpipe flange. (Fig. 1) Move rearward and to the side for working clearance.
Loosen (but do not remove) the v-clamp at the turbo outlet, then shake the downpipe from below to loosen at the turbo outlet.

Remove the MAP sensor on the firewall (Fig. 2) to create sufficient working area for the Sawzall^®. Remove the transmission dipstick and tube. To keep debris or metal shavings from getting into the exposed end of the dipstick tube under the vehicle, place a clean, large rag or wiper in the opening. (Be sure your rag or wiper is big enough that it will not fall into the tube.)

Angle the Sawzall^® high and to the left and cut the downpipe approximately 4 inches from the clamp which connects it to the turbo. (Fig. 4) The object is to remove the "cobra head" from the upper end of the downpipe so that it is possible to drop the remainder of the pipe out of the bottom of the vehicle.

NOTE: We suggest starting with a new blade (Milwaukee #5187 metal cutting blade) because the factory pipe material is tough and dulls blades rapidly.

Remove both sections of the factory pipe, then determine the path for the new U.S. Gear "round" downpipe by inserting the top section of the new pipe into the empty channel which contained the factory downpipe. Take note of where the new pipe will cross the body seam under the vehicle.

Reverse the blade in the saw (or turn the saw upside down) and, from under the vehicle, make two cuts in the body seam approximately 3" on each side of the path where the new pipe will cross the seam. (Fig. 4)

Place the "duck-bill" port-a-power at the body seam and transmission and with a block of wood, fold the seam toward the rear of the vehicle as shown. (Fig. 5) This will create the necessary clearance for the new downpipe to be placed in the path without coming into contact with the body seam.

With the insulating material provided, wrap the top section of the new downpipe and clamp the end. (Fig. 6) NOTE: Soak the wrap in water to make the material more flexible. Remember to leave 2 to 3 inches exposed at the bottom to allow for the slip joint on the lower section.

Install the top section to the turbo outlet with the v-clamp provided. NOTE: The v-clamp included with the kit is a spare in case there is damage done to the factory clamp during removal or re-installation. Do not tighten at this time. Position the top edge of the 3" Torca clamp provided flush with the top edge of pipe. The clamp must cover the slots. Finish tightening nut to approximately 60 ft. lbs. (NOTE: If torque wrench is not available, tighten nut until 13-14 bolt threads are exposed beyond nut (13/16" — 7/8"). This is equivalent to the diameter of a nickel. (Fig. 7)

Re-attach the catalytic converter to the flange, but do not tighten.

Starting at the flange, position all the components for proper clearance and begin to tighten, working up the pipe toward the turbo. With the downpipe in the proper position, tighten the turbo v-clamp to 50-75 in.lbs. Re-install the transmission dipstick assembly and the MAP sensor. Start the engine and check for exhaust leaks.

Be sure to check for sufficient clearance (you should be able to put your finger between the Downpipe and the truck's body) around the entire Downpipe so that Downpipe does not make contact with the vehicle's firewall, transmission, crossmember, etc. Once you have completed the visual inspection for clearance, check for torque movement of the new Downpipe. To do this, set the emergency brake and start the engine. Put the transmission in a forward gear and turn the steering wheel all the way to the right and all the way to the left. Put the transmission in reverse and repeat turning the steering wheel all the way to the right and left. If you hear the Downpipe vibrating against the vehicle, you will have to increase the clearance around the Downpipe. If you do not hear any Downpipe vibration or rattles, then proceed with a test drive of the truck. This completes the installation of the new Turbo Downpipe.

FIG. 1	FIG. 2	FIG. 3
FIG. 4	FIG. 5	FIG. 6
FIG. 7

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Last modified: 10/18/06