i had taken my 92 4x4 to two different exhaust shops and they say you can't go turbo back 4" cause the transfer case is in the way. that looked like a problem to me as i pointed it out to them. so how do you get 4" by the transfer case. they said the only way they could do it was go 4" to 3.5" then 4" past the case. i said no thanks,theres got to be another way to go 4" alll the way!!!!

 

there is... RSWORDS installed a 4" expandit exhaust kit, it's a very tight fit but it wont touch either as long as the trans and engine dont move too much and the whole exhaust doesnt move too much, other than that; it will absolutely fit... or just tell them to stick the pipe in a vice and oval it slightly, i think you can even get a piece of 5 to fit if you squeeze it enough

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i'm suprised you found a place that bends 4"... most places go up to 3... 3.5 if your lucky
also probably for the same price and better quality you can just get that kit from expandit. custom exhaust from shops dont run cheap... especially if you force them to do something they dont want to b/c they cant slam it out in an hour or so

 

VERY tight but it works! I think it would be VERY hard and time consuming for a shop to figure out the bends. Looks like lots of trial and error to get it right.

Expandit and Stans sells a kit.

Here is mine

https://www.dieselbombers.com/5-9l-r...its-turbo.html

 

 

There are four 4" exhaust kits that I know of.

Bullydog and Expandit (they might be the same thing, they were around the same price when I was looking.)

Then there is Rip Rook's system at Source Automotive Performance Diesel and Stan's system at Stan's Headers, standard and custom high performance header designs for automotive and marine engines.

Rip's and Stan's systems are way more expensive than the other two, but I know people with all the systems, and they all love them. No matter which one you get, you'll love it.

 

I had to clearance my 4"magnaflow on my 85 prospector with nv4500.theres not enough room for the passenger side transfercase

 

I installed a Stans 4" turbo back on my 93 D350 4x4 dually in about 2.5 hours, and had lots of clearance. I did have my 3,000 camper on to insure frame/rear shock clearance. It was expensive but easy and no mods!

 

i had the same problem with mine.the 4inch down pipe is what killed me.. cause of the tranny dipstick was rite in the way.. . so i just welded a 3/12 to the 4 inch. and went to 4inch after the tranfercase. was the only thing i could do. unless i ran it under the fram.. i was wanting a hood stack. but nooooooo. they would not do it.. but i dont think it hurt my egts very much.. from 4 to 3/12 back to 4inch. but water/meth will help that out.. i would like to get a 4inch all the way. like i said.. the dipstick is what killing me.

 

where there's a will there's a way.... sould have gotten a flexible braided stainless steel one off summit... granted its like 70 bucks

 

there is a place here in Wyoming up in dobuis Wyoming that does exhaust sytems. i tried to get one of them but unfortunatley they decided not to answer phone calls or emails.