best down pipe/ installation tips; 1996 250 - Ford Powerstroke Diesel Forum
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post #1 of 12 Old 12-09-2012, 04:59 PM Thread Starter
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best down pipe/ installation tips; 1996 250

I'm sure this question has already been answered, but im looking to swap out my stock flat down pipe for a 3" pipe.
however I'm leaving my stock cat in it and some aftermarket dps wont fit onto the factory cat. (MBRP)

my questions are:

Which is the best dp to go with? (since some modification will be needed to get the down pipe onto my factory cat)

also what modifications have y'all encountered swapping down pipes?

any help is appreciated,
thanks!
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post #2 of 12 Old 12-09-2012, 07:32 PM
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If you use the search you will find a bunch of threads about it.

My Truck
97' F-250HD. ECLB. 66,000 miles. 7.3. E40D. 6637 Filter. 5" Exhaust. Deleted EBPV. CCV mod. 45 gal. Transferflow Rear Tank. Stock for now. Dana 60 in the works.
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97' F-250HD. ECLB. 150,000 miles. 7.3. E40D. 4" Exhaust. Work Truck.

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post #3 of 12 Old 12-09-2012, 08:56 PM
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I don't know for the stock cat. But I think the Diamond eye one will bolt right up. basically just the cut the old one out, cut the pinch weld on the firewall a bit, bend the firewall up a little and slip the new one in.

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post #4 of 12 Old 12-09-2012, 10:59 PM
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Why not delete the cat and let your truck breathe and live a happy life?

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post #5 of 12 Old 12-10-2012, 04:21 AM
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I just posted this in another thread but when i was installing mine i wish i had this info so i'll just post again.
When you decide to upgrade the factory pancake downpipe, find a scissor jack and use it to push your firewall in a little bit. This will save you a ton of time and frustration.
I spent quite some time trying to fit my diamond eye DP in there and it was not going to fit, but as soon as i used the scissor jack and moved the firewall it fit just fine.
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post #6 of 12 Old 12-10-2012, 09:49 AM
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now thats a great idea, i used an air hammer and cut the pinch weld out with it fit fine after that, i used a diamond eye and it went rite on to my factory cat, good luck with yours bud

-Kris-
2011 f150 ecoboost 4x4 323/452 on php dyno 11/16/13
1995 CCLB DRW 324K
2001 CCLB DRW 319K
Dp tuner infinity, exhaust, intake, chipped, tricked, and wrecked


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The stock downpipe in an OBS is flat because I'm a ginger.
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Well at least you caught the loose bolts before they cause any damage. Nothing worse than a sloppy hole
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post #7 of 12 Old 12-19-2012, 07:46 AM
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when you guys do add an aftermarket down pipe, do you remove all of the insulation from the bottom/firewall area of the cab?

1996 F250 XL 7.3 PSD ZF5 Red SCLB ...79k miles and show room stock

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post #8 of 12 Old 12-19-2012, 02:04 PM
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Quote:
Originally Posted by Buck Futter View Post
I just posted this in another thread but when i was installing mine i wish i had this info so i'll just post again.
When you decide to upgrade the factory pancake downpipe, find a scissor jack and use it to push your firewall in a little bit. This will save you a ton of time and frustration.
I spent quite some time trying to fit my diamond eye DP in there and it was not going to fit, but as soon as i used the scissor jack and moved the firewall it fit just fine.
I wish I had thought of that...
I bought a porta power and used the duckbill to push the firewall back.

97 F350 CCLB 4x4 PSD
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post #9 of 12 Old 12-27-2012, 06:46 PM
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Quote:
Originally Posted by wishIhada5.0 View Post
when you guys do add an aftermarket down pipe, do you remove all of the insulation from the bottom/firewall area of the cab?
I am really fretting about this. Am collecting pictures of this so I can focus on the exact area needing clearancing and how to do it the least destructively as possible.

Denton, TX

I envy those that know exactly which modification to make and in the most logical of sequences. But not enough to trade for my meanderings and misfires.

1996 F250 crew cab/short bed, 4x4, auto PSD, 6637 air filter, interior grab handles, stainless window vents, remote door locks work with engine running mod.
Link to my D60 refurb and OBS swap thread
Link to my OBS air vent R&R thread
Link to my grab handle install
Link to my tire size comparison pics
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post #10 of 12 Old 12-27-2012, 06:57 PM
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i bought a $26 air hammer at home depot, came with 4 bits, cut the weld in 2 spots and used the handle from my floor jack to bend it down by prying on the motor (bent my floor jack handle btw), you will need to cut the cobra head off the stocker to pull the rest down, took me a while but i used short blades, long blades would have made a lot quicker work

-Kris-
2011 f150 ecoboost 4x4 323/452 on php dyno 11/16/13
1995 CCLB DRW 324K
2001 CCLB DRW 319K
Dp tuner infinity, exhaust, intake, chipped, tricked, and wrecked


Quote:
Originally Posted by marine5811
The stock downpipe in an OBS is flat because I'm a ginger.
Quote:
Originally Posted by alberta 7.3
Finding a decent woman is like shopping for a used truck. You spend most of your time picking through the money pits, wrecks, and basket cases until you find one that you can tolerate
Quote:
Originally Posted by JJFLASH
Well at least you caught the loose bolts before they cause any damage. Nothing worse than a sloppy hole
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