EDELBROCK CAT-BACK EXHAUST SYSTEMS
for 1999-2002 5.4L Ford Expedition 2 & 4 WD
Catalog #5782
INSTALLATION INSTRUCTIONS
Please study these instructions carefully before installing your new Cat-Back Exhaust System. If you have any questions or problems,
please contact our Technical Hotline at:1-800-416-8628, 7:00 am to 5:00 pm, Monday through Friday, Pacific Standard Time or
e-mail us at edelbrock@edelbrock.com . Please fill out and mail your warranty card.
Suggested tools needed for installation:
❑ 3/8” ratchet with SAE and metric sockets.
❑ 9/16” & 15mm wrench
❑ Jackstands and jack
❑ Liquid penetrant and rubber lubricant
DISASSEMBLY
1. Raise vehicle and support with proper jackstands for
the weight, leaving the suspension hanging.
2. Use caution around hot exhaust systems to avoid burns.
3. Use penetrating oil on all nuts and bolts.
4. Remove the bolts and clamps from the system and
lubricate the rubber hangers.
5. Use a long pry bar to pull the rubber hangers off of the
pipe hangers.
6. Remove the old system. In some cases, you will find it
easier to cut the overaxle pipe to remove it.
ASSEMBLY
1. Align notch in I-pipe supplied with aligning pin in factory
assembly, then clamp the intermediate pipe to the
catalytic converter Y-pipe assembly with the stock
clamp or 2-1/2” clamp provided and just snug it so you
can adjust the pipe easily on the catalytic Y-pipe
assembly.
2. Slip the muffler onto the intermediate pipe with a 3”
PARTS LIST
Qty. Part # Description Qty. Part # Description
❑ 1 25-5506 Muffler ❑ 1 23-4034 Hanger Assembly
❑ 1 25-3135 I-Pipe Assembly ❑ 1 46-5185 2-1/2” U-Clamp
❑ 1 25-3136 Overaxle pipe ❑ 1 46-5186 3” U-Clamp
❑ 1 25-3137 Tail Pipe ❑ 2 82-7231 3/8 I.D. Washers (Spacers)
❑ 1 23-4033 Hanger Assembly
clamp on the front. The offset of the muffler is the inlet
(front) on these vehicles. Snug the clamp so you can
adjust the pipes.
3. Install muffler hanger/clamp assembly #23-4033 into
stock rubber hangers.
4. Install overaxle pipe into muffler and rear hanger clamp
onto the stock rubber hanger. Install tailpipe into rear
hanger clamp assembly.
5. Working from the front of the system, align and tighten
each pipe from the cat-back.
6. Check for clearance to body, frame, and driveline as you
tighten the system from front to rear.
Note: Ford uses two different length rubber hangers to
support the exhaust system depending on the year of
the vehicle. You may find it necessary to lower the
overaxle pipe away from the frame. This can be done
by installing the two thick 3/8” washers between the
frame and the factory exhaust support bracket bolted to
the frame.
7. Check for leaks and correct, if necessary.
WARNING: Exhaust gas contains carbon monoxide, a deadly invisible gas. Correct any leaks before driving.
Edelbrock Corporation
2700 California Street
Torrance, CA 90503
Toll-Free Tech Line: 1-800-416-8628
Office: 310-781-2222
©2002 Edelbrock Corporation Rev. 2/02
Tech E-Mail: edelbrock@edelbrock.com
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