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MagnaFlow Turbo Back Exhaust System Installation - 2003 Ford F-250

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How to Install the MagnaFlow Turbo Back Exhaust System on a 2003 Ford F-250

All right, today on this 2003 Ford F250 Super Duty Super Cab, we're going to show you part number MF18985. This is a MagnaFlow Custom Series Turbo Back Exhaust System constructed from aluminized steel. This is basically a steel exhaust with a protective aluminum coating on top of it. All right, this is what the exhaust looks like once installed on the truck. Right off the bat, we can see that we have it routed towards the right-hand side of a truck, and we have a diameter of 4 inches. It is a steel construction with an aluminum coating on the outside and on the inside of the pipe. It uses 1/2-inch thick rods welded to the pipe here, and it goes up to the factory rubber hangers on the truck.

This also comes with all the band clamps needed for all the junctions on our exhaust. Now one exception to one of the joints here is that it uses a U-bolt clamp right here that also doubles as a hanger going up to the factory hangers up on top. The kit comes with different-sized tubings for different configurations of truck, like standard cab, long bed, extra cab, crew cab, so you may or may not end up with an extra piece of pipe. If we follow this pipe here, which is the lower downpipe, you can see it has a bend in it to accommodate the cross member here, as well. The last piece is the downtube pipe here that goes up to the turbo on top. Now, that uses the original factory clamp up at the turbo. Next, we'll go ahead and show you how the MagnaFlow Exhaust System gets installed onto the truck.

Our first step is to go ahead and remove the pre-existing exhaust system. In this case, we don't have to worry much about it because it practically removed itself. The new exhaust will actually use the original rubber hangers, so we need to keep these guys. There'll be one location here, these 2 rubber hangers in front of the axle, and you can see we still have some remnants left over. There's a hanger here and one more up by the crossbar just by the transmission. Now that we've found the rest of our original exhaust, we need to go ahead and remove it.

In this case, it's just easiest to go ahead and make a cut in the exhaust next to the transmission right here because it's the easiest to remove. This is our transmission right here, so we'll cut somewhere in this vicinity right here so we can take the whole pipe and bring it down. Let's get our leftovers ready, so we'll go ahead and pull out the remnants of the exhaust from our rubber hangers. Now, typically the exhaust would be in place so you can have something to push, pull, or pry against to remove the hanger, but you can also get this exhaust tool that will help remove the components, as well. It also helps to spray it down with some lubricant to help remove them. These components I just took off are really not stock, so maybe a conventional push-in fastener.

Okay. I'm just trying to get that last little bit out because when I cut them, they'll just come down and out of the way. There it is. Cool. Next, my favorite tool of choice, a Sawzall. All right, we'll go ahead and put a strap around the other end. Okay. We use a strap to support the other end for us so it'll be easier to take down. All right, now we can go ahead and remove the rest of our exhaust. We're underneath the hood of the truck, and we need to go back towards the firewall and release the clamp that goes from the turbo down to the pipe. This band right here, we have to loosen up this nut with an 11-millimeter socket. You might want to notice how much effort it took to loosen it up, so you've got the same amount of effort back into it when you tighten it down after you put the new exhaust in place. This clamp you want to keep because you don't want to lose it because it doesn't come with the new one. It may be a good idea to spray down a clamp with some penetrant to help loosen it up from the exhaust tube. It's been there from the factory, and it's probably rusted itself together pretty good. Okay, we'll give a couple of taps to the mount to help work it loose. There it is. Okay, we'll go ahead and work it loose. There. Good riddance. Once that pipe's down, we'll go ahead and replace it with the new pipe. It has a larger diameter around this part here than the original one did, so it'll give a little more extra breathing room for the engine. We'll go ahead and put that up in place. We'll work it up in there. It's going to be tight because this extra diameter is going to take up some extra room up there. At this point, you want an extra set of hands to help hold the exhaust up or to guide the top part of the exhaust back onto the clamp. All right, now we've got our clamp freed up. We'll go ahead and show you how it works real fast because you've got to do everything inside there, but once you have this nut loosened up as far as you can, you can squeeze it and pop it loose to get a little more extra working room. Then the flanges on the turbo and the new pipe have to fit inside this groove right here, so we'll line the pipe up and the turbo together. We'll re-clamp somewhere in the middle of that, and then we'll just go ahead and put our clamp back together and tighten it up. You definitely want a third set of hands for this. Okay, we'll take our clamp and push it towards the turbo, bring the pipe up. Okay, once we have our clamp in place, we'll go ahead and snug it down just so I'm taking the slack, but we'll still have to make some adjustments to it, so it needs to move around just a little bit. We've got our upper downpipe in place, and we can still move it, so that's what we want, just loosely, but still it'll hold itself in place. Then we'll go ahead and install our lower downpipe. This is the lower downpipe, and we've got our hanger right here and a clamp. Our clamp is going to go onto the end of our pipe right here. Make sure you have the nut pointing the way you want it when it's eventually installed. We'll go ahead and put this into place. Slide this on the other pipe and this into the pre-existing rubber hanger. It's also a good idea to put some lubricant on the hanger before we put our new pipe into place. We'll push our tube in as far as we can. We can always pull back out if we need to. We'll go ahead and slide our clamp in position. This will get snugged down with a 15-millimeter socket. Now, onto this pipe here, we'll install another clamp and a 20-inch extension pipe. This pipe does not have a bell on either end, so it goes right here. All right, now we'll go ahead and take our next pipe, which will measure out to 30 inches, and add that to the end of this with another clamp. Next we'll go ahead and install a hanger clamp on our pre-existing rubber hanger here. Once again, we'll add some lubricant to it. Then we'll just go ahead and install the clamp. Let's go ahead and put our pipe over the top of this. Okay. Take our U-bolt and put it over the top through the bottom part of a clamp. We'll install 2 flange nuts. All right, things are still going to be a little out of shape right now because we've still got to put in the rest of our system. So we'll go ahead and work with our tube that goes up and over the axle, which will be the tailpipe extension. Next, we'll go ahead and put our 18-inch extension into place with another clamp. We'll let that sit for now, and we'll then work on our next hanger right here. Now, we'll go ahead and do some pre-assembly on our next hanger. Take a bolt and our flat washer, put it into the slots, and then another washer and a lock nut. We'll go ahead and tighten these down a little bit to make sure we still have enough room to adjust it. All right, we'll snug these fasteners down using the 1/2-inch wrench and socket. Let's go ahead and install this part of the hanger into your rubber hangers in the truck. Let's go ahead and let it sit for now. We'll take our tailpipe extension. That goes over the axle. Slide it into place. We'll put our clamp into position on top here and then install our U-bolt. Now we can go ahead and put our tailpipe into place, once again the clamp, and we'll spray down the rubber hanger. Okay, at this point, we've got all our components installed. It's just a matter of aligning the components to make sure they're about a 1/2 inch away from everything else around it and then tightening down the clamps. With all the exhaust loosely installed, we'll go ahead and start tightening down. Again, we'll start the clamp by the turbo here and work our way back. We'll make sure that our first pipe here is sitting the way we want it so we can go ahead and tighten it down. All right, now, we'll leave this hanger alone because this is used on an as-needed basis. We'll position our clamp on this junction right here, and we'll tighten them down as evenly as possible. Let's go ahead and tighten down our clamp right here since the rest of our hangers are all in position. All we've got to do is just tighten these guys down. With all our hardware hand-tightened, we'll go ahead and give the exhaust the shake test, make sure it's not rattling against anything. Okay. It looks like everything is stable, and we have this one clamp here. It's just use as needed. I think we'll go ahead and just leave that one off because there's another clamp less than a couple feet away. Then we'll torque down all the clamps as specified in the instructions. All right, with everything assembled, let's go ahead and turn on the engine. We'll go ahead and listen to the sound of it, and we'll check for leaks underneath the vehicle. All right, with everything installed, let's go ahead and take it for a test drive and listen to the exhaust now. With that, that'll finish it for part number MF18985, the MagnaFlow Custom Series Turbo Back Exhaust System in aluminized steel on this diesel 2003 Ford F250 Super Duty. .

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