Iam getting ready to put a 3" exhaust on my truck this is the first mod. . Can someone tell me if there is any tricks or helpful hints? How does that down pipe hock to the turbo? That looks like the only hard part! 1996 6.5 TD 162000 miles

Once you get the old one out, the hard parts done. Putting the 3" downpipe on is easy just turn it slightly to get it in and then it will mate up like it should. I cut my old one out by cutting right in front and behind the CAT and unbolting the 4 bolt exhaust flange.Edited by: quantum mechanic

What type of connection is it at the turbo clap or bolt on ?

The turbo turn down and the down pipe both have a flange that mates up and the stock 10mm bolt pipeclamp works well to hold it tight. You don't have to remove the airbox but it helps access the clamp's bolt.

Thanks I am ordering today and this will help. I just wanted to be sure I could do it myself.

I used a sawzall with a bimetal blade to remove the CAT. It would have alot more work to unbolt the crossmembers to take it out.

Remove the coolant resevoir. You do not have to drain coolant or disconnect hoses, but if you unbolt the thing off the firewall, you will have lots more room to attach the clamp on the turbo outlet spigot.


I struggled for 45 profanity-laced minutes trying to get that damn clamp on, untill i unbolted the coolant jug. Then it was a 5 minute job.


Tim

Be careful when reinstalling the new downpipe. There isn't a lot of clearance between the pipe and the fenderwell, frame and crossover coupling. You may think you have it aligned properly, only to find that it moves in one direction or another when you tighten the turbo/DP coupling. Been there, done that. Then resonance coming from a vibrating downpipe isn't cool.