Put in new up pipes- what a PAIN! - Diesel Bombers



99-03 7.3L Performance Discussion of 99-03 7.3 Liter Ford Powerstroke Turbo Diesels Related To Performance And Longevity

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Old 03-07-2013, 12:40 AM
Colotow's Avatar
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Join Date: May 2008
Location: Tooele, Ut
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Default Put in new up pipes- what a PAIN!

Put on my new bellowed up pipes.

Got the Dorman 679-005 kit, reasonable price, they were delivered, checked them out, so far so good. Test fit, holes lined up, bolts all start with fingers, eyeball check threads look good.

The made in china cast into it should have been a tip off.

then I tried to put them on....

First, the collector wouldn't seat to the back of the turbo. Pulled it back off, compared it to the original, the locating pin was bent about 45* and mushroomed. So, couple hours later, in an unheated garage in Utah in march, I had it filed and got it to fit.

Got the right pipe in place, bolts finally started (miserable tight fit with a 4" downpipe), left one went in ok, bolts started. Went to tighten everything up, using a 1/4 drive ratchet and 2' of extensions, and SNAPPED one of the bolts going into the collector. GRRRRRR!!

Pulled it back off, started looking. Bolts supplied with the kit, are too long! Same length as the OEM, but the flanges on the new pipes are thinner, the bolt bottoms out 3/16" before the flanges touch.

Had to cut 1/4" off each bolt, clean up the threads, then go through the same shoulder dislocating contortions all over again. And, since I'd cut the bolts, they were a bit square, so they did not want to go in easy.

So, it's together, sounds a lot quieter, boost comes up quicker. The pipes themselves looked good, clean bend, clean flare, good welds.

Just be warned, test fit and snug everything all the way down on the bench before you try to put it on.

Oh, and to make it more fun, the truck now has an 8" lift and 40" 22.5's on it. I'm really tired of climbing up and down off of it right now!
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