Engine/Transmission (1994 - 1998) 4" Exhaust

[Robin]

Installed a 4" exhaust on my '97 dually. Used SS 4 inch clamps, nevertheless was worried about something coming apart since I have a U. S. Gear Decelerator exhaust brake midstream in the pipe. (The muffler is where the cat was. ) There can be at least 55 lb of pressure when the brake is engaged.



There are two connections that would have pressure on them. The first is where the exhaust pipe connects to the downpipe. The second is where the exhaust brake is attached. So just past each of the 4 inch clamps, I drilled a single hole through both pipes, inner and outer, using a #7 bit. Then I tapped the holes with a 1/4 inch fine thread tap. Next I cut two stainless 1/4 inch fine thread bolts so that when screwed in with a flat washer and lockwasher under the head, only a couple of threads would be in the exhaust stream. This definitely prevents the joint from blowing apart. Since then I have checked that both bolts have remained tight.



BTW, the 4 inch exhaust system came from Jerry Jardine. It is not stainless but the aluminizing has not discolored a bit after 1000 miles of heavy hauling in the mountains of West Virginia, exhaust temps up to 1350. The system went together easily. Of course I had to cut the exhaust pipe to install the brake.

 

[Robin]

BTW, forgot to mention, I have the engine turned up so I get 36 lbs boost. With the old exhaust system, I had to watch exhaust gas temp closely. At full boost it would climb to 1450 and I had to back off. Now the temp runs 200 degrees cooler.

 

[Bseg]

That exhaust sounds exactly what I am looking for. Do you guys get the "drone" noise when you take the CAT out? I'm considering getting one, just don't want some un-wanted noise that I can't live with.

 

[Boomer II]

Originally posted by PKemp

I just have to tell you about this, I was most impressed. I ordered, received, installed and simply marvelled at my new 4" stainless steel exhaust system ordered from Diesel Performance Parts. From start to finish took me about 40 minutes to install. Everything (all hangers already welded on) was where it exactly was supposed to be. Slipped in bolted up and walked away... . done! And I did it while laying on the ground with no special tools. No jacks or lifts.

Exactly as advertised, a rare thing these days. Has an impressive deep mellow tone, no cat and a cool flow thru muffler. And the turbo even seems to feel better. Sounds better too. Many Kudos to Mark Craig at DPP for his help when ordering also.

Great product exactly as advertised... ...

Man, you fooled me, I was trying to take my old system off w/out tearing it up, three hours later I'm going to finish sawing it off tonight. I sure hope it goes on in 40 minutes, the taking off has about wore my butt out. :{

 

[TSchuetz]

I had just delt with Mark to set up an account for the NAPA AUTO PARTS store I own. Mark and his people were superb to deal with and have had nothing but great feedback from my customers on the products they have purchased from DPP. Mark, keep up the good work!



Tim



Pewaukee Auto Parts, Inc.

 

[PKemp]

Opps!



Boomer II,

Well, ya know, I forgot the takin out the old one part. I was just so impressed with the puttin in the new one part.

I use a sawsall on the old one and 1 long extension, a socket with a BIG handle at the turbo clamp. Took all of about 10 minutes. Actually took longer to throw the old stuff in the dumpster than it did gettin it out. I forgot how heavy it was an I'm just an old, fat, funny lookin guy.

Sorry about that.....

 

[Boomer II]

I'm headed that way with the sawzall in a few minutes, I'm really looking forward to the going on part, LOL. I'll let ya know how it went later.

 

[Boomer II]

One cut, done deal, you were right, it went on like a glove. Oo.

 

[Mark Craig]

TSchuetz,



Hey small world what you doing here????!!! Glad we could help, that's what we do!



Mark @ DPPI

 

[HoleshotHolset]

TSchuetz:



Could TDR members get a 'garage discount' at your NAPA store?



Matt

 

[TSchuetz]

TDR discount

you bet!!



more than happy to extend discounts to TDR members.



Phone (262) 691-1100. If I am not in... ... ... . just leave your phone

number and that you are a TDR member, @ I will call you back.



Thanks,



Tim

 

[HoleshotHolset]

Wow - I was just kidding. I'll have to keep that in mind.



Pewaukee isn't too far from here.



The parts stores around here won't cut any deals... I'm used to getting garage discounts back where I used to live.



Matt