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, burns more fuel in the combustion chamber adding additional horsepower and fuel economy. This instruction set covers the 4” Rapid Flow Exhaust Aluminized Dual Exhaust designed specifically for the 7.3L Power Stroke.
RAPID FLOW INSTALLATION Exhaust Components 1. Down Pipe 2. Intermediate Pipe 3. Straight Pipe 4. Muffler 5. Passenger Front Piece Tail Pipe 6. Tail Pipe Tip (2 Pipes) 7. Driver Front Piece Tail Pipe 8. Hanger Bracket 9. Y-Pipe 10. Clamps (7 pieces) 11. Hangers (5 pieces) A. Intermediate Pipe B. straight Pipe C. y-pipe D. Passenger Tail Pipe Tip E. Driver Tail Pipe Tip 4. 3. 7. 2. 9. 8. 6. 1. B. A. C. D. E. 11. 5 Rapid Flow Exhaust # 81222 10. 5.
RAPID FLOW INSTALLATION Removal of Stock Exhaust System In these steps you will remove the stock exhaust system. Tool s Needed: • Sawzall • Silicone Spray Lubricant • 7/16” Wrench • Channel Locks 1. Cut Exhaust Behind Muffler 1. Use a sawzall to cut the exhaust immediately behind the muffler. 2. Cut the exhaust on one of the Straight Pipes in front of the muffler. 3. Use a Sawzall to cut the exhaust system at the bottom of the Down Pipe. 2. Cut Straight Pipe in front of Muffler 4.
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 in the above diagram. 7/16” 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 a 7/16” deep socket. 4. Hang the Intermediate Pipe from Hanger A and secure the pipe to the Down Pipe using one of the supplied clamps.
RAPID FLOW INSTALLATION 8. Install the Passenger Front Piece Tail Pipe into the lower pipe coming out of the Y Pipe. Ensure that the bend is directly over the axle. Secure the connection with a clamp. At this point don’t tighten completely. Wait until the entire exhaust is installed before tightening everything down completely. Hanger C Y-Pipe Install Front Piece Tail Pipe 9. Install the Passenger Tail Pipe Tip in the Passenger Front Piece Tail Pipe and hang from Hanger D. Secure with a clamp.
RAPID FLOW INSTALLATION Muffler Straight Pipe 13. At this point it is time to install the other Straight Pipe. You will need to measure the Straight Pipe to the correct length, keeping in mind that you will need to have an extra 3 inches of overlap when you cut the pipe. 14. 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. 9/16” 16.
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.
RAPID FLOW INSTALLATION Rapid Flow Exhaust # 81222 12 12
Doc.# 81222-99 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.
