INSTALLATION Manual Ford 7.
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 which burns more fuel in the combustion chamber resulting in additional horsepower and fuel economy. This instruction set covers the 4” Rapid Flow Aluminized Exhaust for the Ford 7.3L Power Stroke.
RAPID FLOW INSTALLATION Exhaust components Tools Needed 1. Down Pipe 2. Second Piece Down Pipe 3. Adapter 4. Straight Pipe 5. Muffler 6. Passenger Front Piece Tail Pipe 7. Tail Pipe Tip (2 Pieces) 8. Driver Front Piece Tail Pipe 9. Hanger Brackets 10. Y-Pipe 11. Clamps (7 pieces) 12. Hangers (4 pieces) A. Straight Pipe B. Y Pipe C. Tail Pipe Tip D. Tail Pipe Tip - 9/16” Wrench - Sawzall - Silicone Spray Lubricant -7/16” Deep Socket -Socket Wrench -Channel Locks -20” Extension A. D. B. C. 11. 12.
RAPID FLOW INSTALLATION Removal of Stock Exhaust System In these steps you will remove the stock exhaust system. 1. Use a sawzall to cut the exhaust immediately behind the muffler. 2. Cut the exhaust using a sawzall 4” behind the catalytic converter. 3. Unbolt the flange at the front of the catalytic converter and remove the catalytic converter for installation later. 4. Cut the exhaust at the bottom of the down pipe. #1 Cut Exhaust after muffler 5. Cut the flange off of the turbo down pipe.
RAPID FLOW INSTALLATION Installation of the Bully Dog Rapid Flow Exhaust System In these steps you will install the Rapid Flow Exhaust System. 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. There is a hanger on the Catalytic converter that will be reused . Hang the Hangers Fire Wall Adjustment Area 3. In order to fit the new Down Pipe into the engine bay, the firewall seam might need to be bent or trimmed in order to provide the necessary clearance. If you use either an adjustable wrench or vise grips to grip the seam lip as far as possible and bend the lip out of the way.
RAPID FLOW INSTALLATION 6. Reinstall the Catalytic Converter and secure it by bolting it to the flange on the Second Piece Down Pipe . 7. Install the Adapter on the Catalytic Converter and secure with one of the supplied Clamps. Switch Directions: The next steps will be from the back of the truck 8. Install the hanger bracket on the rear of the driver’s side and hang Hanger C. The hanger bracket will be secured to the frame of the truck using an existing hole in the frame.
RAPID FLOW INSTALLATION Passenger Front Piece Tail Pipe 10. Install the Tail Pipe Tips by tightening up Hanger C and D enough to hold the Tail Pipe Tips in place. Hanger C Muffler Driver Front Piece Tail Pipe Connect Muffler to Y Pipe 11. Install the Muffler by connecting it onto the Y Pipe and then tightening Hanger B. Tail Pipe Tip Hanger D Install Tail Pipe Tip 12. At this point it is time to install the Straight Pipe.
RAPID FLOW INSTALLATION 13. 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. Straight Pipe Hanger A Muffler 9/16” Install Straight Pipe 14. Return to each of the Clamps and tighten with a 9/16” wrench. Again, do not over tighten Clamps. Having any part of the exhaust system in direct contact with any part of the body or chassis will the cause the exhaust to rattle.
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. This extra muffler would take place of one of the straight pipes included with this system.
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