Cutting the drop pipe on a '05 - Ford Powerstroke Diesel Forum
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Old 07-10-2011, 10:12 AM
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Cutting the drop pipe on a '05

I am installing a 4" exhaust system on my '05 in my garage so I will be laying on my back to do this. Is there any "best" place to cut the drop pipe or just cut where it's easiest?
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Old 07-10-2011, 04:54 PM
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Cut it at the as high up on the elbow as you can, and you will be just fine.
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Old 07-10-2011, 05:21 PM
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Thank You kind Sir! But I got to thinking, and that can be really dangerous, should that be the first step to take?
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Old 07-10-2011, 05:57 PM
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I leave the downpipe until last. I take everything else off, cut the pipe in front of the crossmember, remove the rear piece, then unbolt the downpipe from the turbo. Or, remove the crossmember and take it out in one piece. Not difficult, once you dive in you realize it's a lot easier than you'd think.
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Old 07-10-2011, 06:21 PM
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I did it last also, but made the mistake of releasing the marmon clamp from the turbo before I took the sawsall to it, and boy did it vibrate like crazy. Looking back, I would do it just like Daz stated, cut it then remove it from the turbo.
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Old 07-10-2011, 07:27 PM
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Seeing as I don't have a sawsall and not knowing how hard it would be cutting the pipe with a hacksaw it might be easier to remove the cross member. Any thoughts on that?
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Old 07-10-2011, 07:31 PM
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The upside to that is being able to install the stock exhaust if you ever need to. If you don't mind taking the time to remove the crossmember, and can support the trans with it out, that is the route I'd go. I'm always in a hurry, and have no intentions of ever re-using the factory downpipe.
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Old 07-10-2011, 07:41 PM
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I'm like you, always in a hurry! Think I'll go with the hacksaw, can't be that hard of metal.
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Old 07-10-2011, 07:50 PM
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I helped a friend put the exhaust in his 05 a few years back. I remember that we took everything apart and didn't cut anything.
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Old 07-10-2011, 09:33 PM
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Diesel Doctor,

As a 100% disabled Vietnam Veteran it would be almost impossible to find anyone who stands behind our troops more than myself. So therefore, Sir, I am honored to stand beside you.

God bless America and God bless our military, may they come home soon.
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