- 1). Determine the intended purpose of the truck. Is the truck going to be used for strictly off-road or racing purposes? If so, the exhaust system should include long tube headers, 3-inch pipes, and the least restrictive (and thus loudest) mufflers available. If the truck is to be driven on public roadways with any regularity, the exhaust system should include long or short tube headers; at least 2 ½-inch pipes; oval-shaped, multi-chambered mufflers; catalytic converters; EGR valves; and full-length tailpipes.
- 2). Remove the old system. Pay close attention to where the old system was mounted as the factory always mounts the exhaust system so as not to interfere with any moving parts. You will want the new exhaust system to follow the same path as the factory system to avoid costly damages. The only exception to this rule is if the truck is equipped with an aftermarket lifted suspension, in which case a new path can be planned for the exhaust system to follow to take into account the increased wheel travel associated with these systems.
- 3). Install the new exhaust system. Be sure to replace the old exhaust manifold gasket, collector flange gasket and tubing hangers, as these parts wear out quickly and are not ever suitable for re-use. If the new exhaust system requires welding of any kind, consider having a professional perform the work. This is always advised because if even a tiny hole is left in the system exhaust gases will leak out, reducing the effectiveness of the system and possibly bypassing critical components such as the EGR valve, mufflers or catalytic converters.
- 4). Tune the engine after installation. To take full advantage of the increased airflow created by a performance exhaust system, the engine must be tuned. This will require professional assistance if the truck is equipped with an electronic control system. If the truck is equipped with a carburetor and no electronic control unit, simply adjust the fuel flow and spark timing until the engine is running smoothly.
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