Tips for installing 4" downpipe? - Ford Powerstroke Diesel Forum
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post #1 of 17 Old 08-17-2010, 11:03 AM Thread Starter
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Question Tips for installing 4" downpipe?

Got my Diamond Eye system here which I'll install on next days off. I hear the 4" DP can be tough to install so I'm seeing if anyone has advice to get it in there. Thanks!

BTW this system is sweet!!!!


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post #2 of 17 Old 08-17-2010, 11:21 AM
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Come from the Bottom of the motor up extra set of hands will make it easier, make sure once you get everything lined up, keep it all loose for adjustment.

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post #3 of 17 Old 08-17-2010, 11:39 AM Thread Starter
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Do I need to cut or remove anything to make room? I heard some people had to remove insulation or something?


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post #4 of 17 Old 08-17-2010, 11:54 AM
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Like Rescue said, go from the bottom up. It is tight, but a used a bit of 2x6 (so I didn't beat up the lip) and a hammer and it went in eventually. It did take a little bit of the insulation off the firewall though.

FWIW, mine was the Diamond Eye 4" with stainless tip. I think I like the stainless better than the chrome tip that came with my MBRP system on my '01 Ex.
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post #5 of 17 Old 08-17-2010, 05:30 PM
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yes from the bottom with patience, I also put a small tear in the insulation but reached in and smoothed it back out. Mine is a BD Xhale 4" system.
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post #6 of 17 Old 08-18-2010, 03:55 AM
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No need to touch the insulation, put it in from the bottom where it will kinda hang by itself then go up top. With your left hand postion pipe, right hand hold v-band. While holding band snug remove left hand and and tighten vband but not so tight it cant rotate for alignment

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post #7 of 17 Old 08-18-2010, 04:24 AM
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03 and 04 must be a little different from your 06, there was no way to put that downpipe in without hitting the insulation - just not enough room between the engine and firewall.
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post #8 of 17 Old 08-18-2010, 06:06 AM
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03 to 04 are tighter to fit 4 inch down pipes, but the 05-07 have a little more room for a bigger down pipe than the 03-04. so thats why people with the older 6.0 have more trouble.

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post #9 of 17 Old 08-18-2010, 09:43 AM
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put mine in on sat had to cut bolt sticking out of firewall. worried about engine movement on hard acceleration. also strange noise on idle after install?

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post #10 of 17 Old 08-18-2010, 09:50 AM Thread Starter
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Is it possible for a one man installation?


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http://www.powerstroke.org/forum/gen...nt-filter.html

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IIS Stage 1 Turbo, Warren Diesel 155cc/0% Injectors,
Swamps 58v FICM, PHP Atlas 40 Tune, PHP Gryphon Programmer,
5" Diamond Eye Exhaust, DieselSite Coolant Filter,
Knockoff EGR Delete, ARP studs, 33" Toyo MT's
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