Stainless-works Ford F-150 2004-08 5.4L Exhausts User Manual download pdf

2004-2008 FORD F-150 5.4L 2WD/ 4WD

EXHAUST SYSTEM INSTALLATION INSTRUCTIONS

Thanks for purchasing Stainless Works Exhaust System for your 2004-2008 2WD/ 4WD

F-150 5.4L SUPERCAB with 6.5’ bed or SUPERCREW with 5.5” or 6.5’ bed. We have

gone to great pains to make sure that our exhaust systems fit and sound great. Please

follow these steps to ensure that your installation goes as planned.

1. Stainless Works recommends the use of Hi-Temp RTV sensor safe silicon gasket

maker as an option to or in conjunction with the use of factory gaskets. The

recommended Oxygen Sensor Safe RTV is either Valco All-in-One Aluminum or

Permatex Copper P/N 101BR available at NAPA, Autozone and other retailers.

2. Disconnect the battery before starting work on the exhaust system for your

vehicle. Reconnect the battery when the job is completed.

3. Your exhaust system can be installed by a weekend warrior but the use of a lift is

recommended for ease of installation. If using a jack, the vehicle must be placed

on a level hard surface and jack stands are required for safety reasons.

INSTALLATION FOR EXHAUST SYSTEM TO FACTORY CONNECTION PT.

4. Disconnect battery.

5. Raise and support vehicle.

6. Loosen double wide exhaust clamp at back of factory Y-pipe and save clamp for

later use.

7. Remove the hangers from the rubber insulators and remove the exhaust. If using

a lift, the exhaust can be removed in one piece, but if not, the tailpipe may need to

be cut in half for removal.

8. The pictures at the end of this document are headers to an under-bumper system,

showing x-pipe and hanger locations before and after the mufflers and at the tips.

9. The following instructions are utilized to adjust the length of the Y-pipe based on

the Truck cab/ bed configurations:

10. The Y-pipe length in the box is 29” long. This Y-pipe is designed to be cut to fit

the following truck cab/bed configurations. Cut the front ( the single pipe end) of

the Y-pipe and deburr, according to the lengths described in the following table:

1 2 3

Summary of Contents

Page 1

2004-2008 FORD F-150 5.4L 2WD/ 4WD EXHAUST SYSTEM INSTALLATION INSTRUCTIONS Thanks for purchasing Stainless Works Exhaust System for your 2004-

Page 2

CAB/ BED AMOUNT TO BE REMOVED FROM REAR OF Y-PIPE FINAL Y-PIPE LENGTH SUPERCREW/ 6.5’ BED 0” 29” SUPERCAB/ 6.5’ BED 7” 22” SUPERCREW/ 5.5’ BED 13” 16”

Page 3

WWW.STAINLESSWORKS.NET 800-878-3635 FAX: 440-543-9183

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Stainless-works Ford F-150 2004-08 5.4L Exhausts User Manual

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