Join Date: Mar 2008
Location: Chaplin, CT
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I would get 1 spare sensor 8C3Z-12B591-D anyway,usually the rear is the problem. Don't heat it up, usually just makes things worse then you can't reinstall the stock parts.
Here's a quick run down:
CAT/DPF OFFROAD Pipe install: NOTE DO NOT INSTALL PIPE WITHOUT HAVING THE PROPER PROGRAMMING IN HAND FIRST, INSTALL WITHOUT PROGRAMMING WILL RESULT IN REGEN/RUNNING PROBLEMS
1. Begin with cool exhaust system, spray the 3 EGT sensor with good penetrating oil approx. 1hr+ before removal begins.
2. Remove the 3 EGT sensors using a high quality 13mm line wrench or crows foot(DON'T HEAT SENSOR, DAMAGE AND RUNNING ISSUES WITH RESULT). Sometimes shocking the wrench helps break them loose, the rear one seems to be the worst.
3. Remove the 15mm nut holding the DPF pressure sensor brkt to the CAT/DPF flange,rotate the sensor brkt away from the stud the free up the hose from the factory nipple(BE CAREFUL,SENSOR IS PLASTIC AND VERY EASY TO BREAK).
4. Remove the 13mm nuts along the outside of the frame that hold the exhaust hanger brkts to the frame(pipe will be removed with hangers,rubbers and brkts still on the pipe).
5. Using a racket strap, apply pressure rearward on the factory muffler/tailpipe assemble to remove it from the factory DPF, set exhaust out of the way to make room to remove the CAT/DPF assemble.
6. Using a 13mm flex socket and extension, remove the 13mm headed bolts that hold the factory CAT/DPF to the down pipe(you don't have to hold the nuts,they are welded to the CAT flange).
7. Using a helper, remove the CAT/DPF assemble and brkts/mounts, THIS ASSEMBLE IS VERY HEAVY AND HELP IS NEEDED TO SAFELY REMOVE IT.
8. Install new pipe with supplied hardward to the down pipe, loosely set height and rotation of pipe to clear crossmember and snug the bolts(you can use and tiedown to hold the rear section of this new pipe and set height).
9. Now install the factory or aftermarket exhaust, if you run into a tight fit you can use a racket type strap to apply pressure forward and wiggle the junction up and down while keeping pressure on the strap.
10. Make sure not to rotate the rear pipe as it may twist the CAT/DPF pipe to downpipe alignment, once all pipes are properly aligned tighten the downpipe bolts,then tighten the clamp between the end on the new pipe and rear exhaust(stock or aftermarket).
11. Install EGT probes with a little never sieze on the threads, install pressure sensor onto pipe brkt with the hardware supplied.
12. Install proper programming BEFORE running the truck! Don't even start the truck while pipe is removed or sensor are unhooked, this will cause problems with the truck running.
13. Start truck and check for leaks,correct if needed. Check of proper clearance of wires,sensor and crossmember, fix if needed.