Received my Kennedy exhaust late this afternoon. Spent a good portion of the evening getting old system out and most of new in.
For the most part it's a one man job, but a second set of hands would have been nice when installing the down-pipe and that Censored clamp. After a couple of failed attempts, I removed the inner fenderwell. Installing the down-pipe is piece of cake after that. Other have said that it may be possible to go bigger - I really wonder about that. It's tight, especially the clearance between the manifold and pipe. IMHO, 3" is plenty.
The rest of the install is pretty straight forward. The foward most support - just in front of the soot trap on the '94, should be removed - trust me, I have the scraped knuckles to prove it.
For those not installing a Cat, there is a transition pipe that fits in between the down-pipe and cross-member offset pipe (CMOP). When properly positioned the end of this section is about dead even with the torsion bar support.
I orderd the 'extended' system. This system is designed for the crew cab, long box, and shorter vehicles. Mine truck is an extended cab, long box. With this said, the next section is the CMOP. For my vehicle it is too long. Just how much too long, I haven't quite determined yet. Anyone installed this system before, and can recall how much of this section was removed? My guess is about the length of the muffler, but more on this in a minute.
Not knowing how much of the CMOP to remove, I moved to the back of the truck and installed the tailpipe. For this I used two points of reference. One, I made certain that the 'axle hump' was directly over the axle, and two, that the tailpipe exit was nearly level with just abit of downward slope so that moisture will run out.
With the tailpipe in place, I slid the muffler on. At this point it gets a little tricky, but with the help of some 'guy wires', jack stands and the hangers snugged but not tight, I was able to maintain the relative position of this 'assembly'.
At this point in the installation I can see that the CMOP needs to be trimmed almost the length of the muffler. (If the tailpipe was swaged, I'd leave the muffler out and just run the cross-member offset into it!)
As of right now, I have not trimmed any pipe. I'm hoping someone that has done this will chime in a give me some advice. (I'd give JK a call but he is normally not open on Sat except for appointments, and this being a holiday weekend, I doubt he'll be in period - I don't blame him!)
If know one chimes in, I'll probably trim the CMOP just about the length of the muffler. One thing to note here is that the 'transition pipe' will slide quite aways into the CMOP. If I use this 'feature' I should have plenty of pipe (CMOP) to play with and there should be no detriment to the system. When I have everything wrapped up, I'll fill in the details.

Sent an email, but pretty much the ay you are doing this is correct. I'd rather not call out a dimension as it is best to work from both ends and meet in the middle. I just run the offset pipe alongside the muffler mark, and cut. If you trim a little short, you can always pull the 3-3.5" transistion pipe back a bit to gain some length.

I'll be around off and on all weekend primarily morning and later nights.

Brother in Law's (wife's car) brakes this am.

Mother in Law's new garage wiring this aft

My Parent's 1000' plus new driveway landscaping Sun and probably Monday. If you've never operated a Harley rake, you should try one. They are so awesome that I bought one! That and trying to rent one off and onfor many days of sporatic work...

If you've never operated a Harley rake, you should try one. They are so awesome that I bought one! That and trying to rent one off and onfor many days of sporatic work...


I want to see a pic of a rake on a Harley :lol:

Sent an email, but pretty much the ay you are doing this is correct. I'd rather not call out a dimension as it is best to work from both ends and meet in the middle. I just run the offset pipe alongside the muffler mark, and cut. If you trim a little short, you can always pull the 3-3.5" transistion pipe back a bit to gain some length.

I'll be around off and on all weekend primarily morning and later nights.



Thanks JK ! Really appreciate the response and vote of confidence. Got a couple of errands to run and then I'll wrap things up under the truck.

And yes, I have operated a Harley rake - mounted on a skid steer. Wish I had one - you can bring your down and leave it here :)

Well, after a minor interuption of putting up trusses on my neighbor's new shop, I finished up the install. Everything went together well. The stainless steel band clamps at the "cat's jammies".

After getting the inner fenderwell back in and everything back in it's place (not to self, do something about batteries and/or terminals), I took it for a short run. I immediately noticed a vibration at idle and when not under load. Turns out I needed to go underneath and make some 'minor' bodywork adjustments. Possibly because of the way I have the down-pipe positioned, or maybe just because of the cramped space, the down-pipe was touching the body seam. When looking at it from under the truck it appeared fine, but with the engine running I could see it touching. So I reached up there with a long punch/bar, gave the body seam some 'encouragement' and folded it over. No vibrations now - just the sound of power and the whistle of the turbo.

If you haven't installed a free flowing exhaust, do so. With less than 5 miles on this system I can notice a difference. No doubt the difference will continue to shine thru when I hook up the tandem and skid steer. Kennedy's system is worth the money. (Disclaimer: I am in no way associated with, nor have I received any compensation from, John Kennedy)

Have a great weekend.

only problem with a Harley rake is that once everyone finds out you've got one....everyone seems to find use for it!!;)

Yup, and a couple of real invoiced jobs, it can be depreciated.

I really enjoy working with my tractor and attachments as it is a nice getaway. While I really should get out on my Harley, I find it rewarding to see what I have accomplished and fun to pl;ay with my toys.

I think if she'd let me, I'd have a skid steer, dozed, and excavator as well...

JK, do you offer a 4" muffler (not glasspack) that you sell individually?