CAUTION: Up-pipe replacement is not for the average hobbyist. Access is very limited. Ford technicians remove the truck’s cab to change these pipes. It is possible to do it without removing the cab with good tools, a lot of patience and some good luck. These instructions serve only as a guide for cab-on replacement. Removal of Stock Pipes Figure 1 Figure 2 1. Apply a penetrating lubricant liberally to all exhaust fasteners and sensors. 2. Remove / relocate the down pipe.
7. Unbolt the EGR/OC pipe from the right-side up-pipe and upper mounting bracket. Refer to Figure 6. Figure 6 8. There is a single bolt bracket (shown in Figure 7 after the pipes have been removed) near the EGR cooler end of the EGR/OC pipe that can be accessed from the bottom. Remove the bolt holding the EGR/OC pipe to the bracket. The EGR/OC pipe cannot be removed from the vehicle but will need to be repositioned numerous times to access the other pipes. Refer to Figure 7. 9.
5. Install the left-side exhaust manifold nuts and tighten the Left-Side Up-Pipe top bolts. Snug all fasteners before finally tightening them all. 6. Place the Right-Side Up-Pipe into position and over the exhaust manifold studs. Figure 11 7. Place a 3-Bolt Gasket onto the turbocharger end of the Right-Side Up-Pipe by starting the bolt threads into the 3-Bolt Gasket. The bolts and the 3-Bolt Gasket hold each other in place while you start the bolts into the turbocharger housing. Refer to Figure 11. 8.