INSTALLATION Manual Ford 6.
RAPID FLOW INSTALLATION TROUBLESHOOTING: If you have questions during the installation of this product, please visit www.bullydog.com/Product_Updates.php. The latest version of these instructions can be found at the same location. Please review the Troubleshooting section on page 9 before calling technical support to cover most common issues. Technical support is available by calling 866-bullydog (866-285-5936). TABLE OF CONTENTS INTRODUCTIONS..............................................................
RAPID FLOW INSTALLATION INTRODUCTION The Bully Dog Rapid Flow Exhaust Systems have been specially designed to allow the lowest mandrel bends in the industry. The lower mandrel bends allow increased air flow which reduces exhaust temperatures, burns more fuel in the combustion chamber. This results in additional horsepower and fuel economy. This instruction set covers the 5” Rapid Flow Aluminized Exhaust for the 6.0L Ford Power Stroke.
RAPID FLOW INSTALLATION Bill of Materials Tools Needed 1. Down Pipe 2. Second Piece Down Pipe 3. Adapter 4. 48” Straight pipe 5. Muffler 6. Front Piece Tail Pipe 7. Tail Pipe Tip 8. Clamps (7 Pieces) 9. Hangers (4 Pieces) - 7/16” Wrench -9/16” End Wrench - Sawzall (Recommended) - Silicone Spray Lubricant -Channel Locks -20” Extension A. Straight Pipe B. Straight Pipe C. Rear of Muffler D. Tail Pipe Tip 10. Gasket and Bolts 10. 5. 3. 6. 4. 8. 7. 2. 9. 1. A. B. D. C.
RAPID FLOW INSTALLATION Removal of Stock Exhaust System Important: It is illegal in all 50 states and Canada to remove the catalytic converter. In these steps you will remove the stock exhaust system. 1. Use a sawzall to cut the exhaust immediately behind the muffler. 2. Then cut the exhaust 4 inches behind the catalytic converter in front of the band clamp. #1 Cut Exhaust after muffler 3. Unbolt flange in front of the catalytic converter. 4. Then make a cut at the bottom of the down pipe. 5.
RAPID FLOW INSTALLATION Installation of the Bully Dog Rapid Flow Exhaust System In these steps you will install the Rapid Flow Exhaust System. Bully Dog’s Exhaust Systems are onecut systems, meaning that you should only have to cut one pipe or less if installed correctly. Tool s Needed: • Silicone Spray Lubricant • 9/16” Wrench • • • 7/16” Deep Socket Socket Wrench Tape Measure 1.
RAPID FLOW INSTALLATION 2. Place all of the supplied Hangers into their appropriate locations as shown in the above diagram. Hang the Hangers 3. Install the Down Pipe. You will use the stock band clamp to secure the Down Pipe to the turbo. Secure the Down Pipe by tightening the stock band clamp with 7/16” a 7/16” deep socket. 4. Secure the Second Piece Down Pipe to the Down Pipe using one of the supplied clamps.
RAPID FLOW INSTALLATION Switch Directions: The next steps will be from the back of the truck 7. Join together the Front Piece Tail Pipe and the Tail Pipe Tip, secure with a Clamp. Hanger C Hang Front Piece Tail Pipe from Hanger C 8. Hang the combined pieces from Hangers C and D. Ensure that the bend of the Front Piece Tail Pipe is directly over the axle. Secure the connection between the two exhaust pieces with a clamp. Hanger D Front Piece Tail Pipe 9.
RAPID FLOW INSTALLATION 11. Once the entire exhaust system is installed, inspect the system to ensure that no part of the exhaust is in direct contact with the chassis or body; adjustments may be necessary. Having any part of the exhaust system in direct contact with any part of the body or chassis will cause the exhaust to rattle. 12. Return to each of the Clamps and tighten with a 9/16”wrench. Again, do not over tighten Clamps.
RAPID FLOW INSTALLATION Troubleshooting/FAQ CONDITION Exhaust Rattle Exhaust is too loud POSSIBLE SOURCES Exhaust Sounds Exhaust Sounds ACTION Either one of the clamps is not tight or the exhaust is coming in contact with the chassis or body. Adjust the exhaust to ensure that no contact is made. If your exhaust seems too loud, Bully Dog can sell you another muffler which will allow you to double stack mufflers.
RAPID FLOW INSTALLATION Rapid Flow Exhaust # 81052 12 12
Doc.# 81052-99 V2.0 Check out more of our Adrenaline Pumping products! Downloaders Intake Systems Triple Dog GT Exhaust Systems ® Free Technical Support at: 866-bullydog (866-285-5936) See More at: bullydog.
