MBRP S6204304 User manual
PLEASE READ BEFORE STARTING
INSTALLATION
While MBRP Inc. has made every effort to ensure that all components of this system are of superior
quality and properly packaged, it is the installer’s responsibility to ensure the following before removal
of the factory exhaust:
•that ALL components shown in the illustration on page 2 are present.
•that ALL mating components fit together.
•that there are no damaged components.
•that the system you have purchased is appropriate for your vehicle year, model and configuration.
•that the system will not interfere with any modifications previously installed.
•that you have read and understand these instructions.
If you have any questions or are uncertain about any aspect of the installation of this system to your vehicle
please contact your dealer before commencing installation.
Installation Instructions for Systems;
S6204304, S6204409, S6204AL
99-03 Ford Excursion
7.3L Powerstroke Diesel
S6204 © 01/06 Page 1 of 3
S6204304 “PRO SERIES” S6204AL “Installer Series”
S6204409 “XP SERIES”
1 PC - Down Pipe 1 PC - Down Pipe
1 PC - Extension Pipe 1 PC - Extension Pipe
1 PC - High Flow Muffler 1 PC - High Flow Muffler
1 PC - Tail Pipe 1 PC - Tail Pipe
2 PCS - 4" Clamps 2 PCS - 4" Clamps
1 PC - Hanger Clamp 1 PC - Hanger Clamp
1 PC - 5" Stainless Steel Tip Tips Sold Separately
Removal of stock system:
1. Loosen the nut on the band clamp located behind the catalytic converter using a 15mm wrench or
socket.
2. If a hoist is being used for the installation, the original exhaust system can be removed in one piece by
removing the passenger side shock. If a hoist is not being used the tail pipe must be cut behind the
muffler to be removed.
3. Remove the muffler and tail pipe from the OEM rubber hangers and separate the stock exhaust at the
slip joint located behind the catalytic converter and remove the muffler and tail pipe from under the truck.
Re-install the passenger side shock.
4. Remove the catalytic converter by removing the two nuts holding the inlet flange together using a 15mm
wrench or socket.
5. Remove the down pipe from the turbo by removing the band clamp using an 11mm socket. Retain the
band clamp for the installation of the new down pipe. Cut the down pipe in front of the transmission
cross member to remove. (Note: The stock down pipe can be removed in one piece by removing the
transmission cross member. It is recommended that this only be done by qualified, trained professionals
using tools and equipment designed to safely carry out this procedure.)
S6204 © 01/06 Page 2 of 3
Installation of MBRP Inc. Performance Exhaust:
1. Install the Down Pipe in the same position as the stock down pipe and attach the flared end to the turbo
using the stock band clamp. Do not fully tighten until all components are in place.
2. Attach the Extension Pipe to the Down Pipe and place the hanger into the factory rubber insulator
located on the frame.
3. Install the Muffler over the Extension Pipe. Refer to the figure on the left
for correct Muffler orientation.
4. Install the Tail Pipe from the rear of the truck, over the axle and attach to
the outlet of the Muffler. Install the hangers into the OEM rubber hangers
located above the outlet of the Muffler. Now install the Tail Pipe hanger
into the OEM hanger to complete.
5. Install the provided Clamps around the pipes where required. Adjust the Tail Pipe and check along the
whole length of the exhaust system to ensure that there is adequate clearance around the fuel and brake
lines or any wiring. If any interference is detected relocate or adjust.
6. Ensure that the exhaust is in place before tightening clamps. Start at the front of the exhaust system and
begin tightening all connections.
7. Install and adjust the Tip to suit. Using a 17mm wrench tighten lock bolt located on the Tip. ATip is not
included with “INSTALLER” or “XP SERIES” kits. ATip may be purchased separately, check with
your dealer.
Congratulations! You are ready to begin enjoying the improved performance and driving experience of
your MBRP Inc. performance exhaust system. We hope you enjoy your purchase.
S6204 © 01/06 Page 3 of 3
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