Edelbrock 5786 User Manual

EDELBROCK DIESEL EXHAUST SYSTEM

for 1999-2003 Ford 7.3L

Crew & Extended Cab, Long & Short Bed

Catalog #5786

INSTALLATION INSTRUCTIONS

Please study these instructions carefully before installing your new Edelbrock Exhaust System. If you have any questions or
problems, contact our Technical Hotline at: 1-800-416-8628, 7am - 5pm, Monday-Friday, Pacific Standard Time or e-mail us at

[e-mail]. Please fill out and mail your warranty card.

Suggested Tools for Installation:

❑ 3/8" and 1/4” ratchet set and metric sockets ❑ 9/16” Combo wrench
❑ Hacksaw, sawzall, chopsaw ❑ Jack and jackstands
❑ Liquid penetrant and rubber lubricant

DISASSEMBLY

1. Lift and support vehicle on correct load rated jackstand
on stable surface.

2. Unbolt I-pipe from turbo downpipe at flange.

3. Cutting overaxle pipe at rear of muffler will make
removing muffler, overaxle, and I-pipe assembly easier,
remove muffler, I-pipe, and overaxle at this time.

4. Remove turbo downpipe clamp at turbo.

5. Remove turbo downpipe. Turbo downpipe can be
removed in one piece by supporting transmission and
unbolting crossmember, or cut turbo downpipe to
remove.

ASSEMBLY

1. Use supplied turbo downpipe V-band clamp, install turbo
downpipe from bottom, snug turbo downpipe to turbo.
Do not tighten at this time!

2. Install I-Pipe and 4” clamp onto turbo downpipe. Rotate
I-pipe for clearance over transmssion crossmember.
Snug clamp.

3. Crew cabs, both short and long bed, and super cab long
bed models will require use of supplied I-pipe extension,
Edelbrock part #25-3202. Some models require that the
extension pipe be cut to length. Crew cab long beds use
extension pipe as supplied. When cutting extension pipe,
measure from expanded end so you are cutting off the
unexpanded end. Slip hanger clamp assembly #23-4043
into O.E. hanger insulators. Some vehicles require two of
these clamp assemblies.

NOTE: On some vehicles, it may be necessary to bend
rear heat shield bracket up to to gain sufficient clearance
for I-pipe.

4. Unbolt stock front muffler hanger from frame rail and
move to pre-drilled holes approximately 8-1/2” forward in
frame.

5. Install rear muffler hanger #23-4045 in factory hangers.

6. Slide hanger #23-4044 over I-pipe. Install muffler with
inlet facing forward. The inlet end of the muffler is the
end with the number stamped on the end cap (#25-

5571). Insert hanger into relocated factory hanger and
snug clamp.

7. Install overaxle pipe and slip into muffler.

8. Install tailpipe hanger (#23-4046) into factory tailpipe
hanger insulator and slide onto the end of the overaxle
pipe.

9. Dual rear wheel applications require supplied tailpipe
extension (#25-3205). Install tailpipe (#25-3204) onto
overaxle and through tailpipe hanger clamp assembly.

10. Starting at the front of the vehicle to rear, align and
tighten all clamps and hanger clamp assemblies. Position
system for clearance around surrounding hoses, lines,
cables, and frame members for best clearance.

11. Make one final inspection for clearance around brake,
fuel lines, and wiring. Drive vehicle and re-tighten
system.

WARNING!!!

Exhaust gas contains carbon monoxide, a deadly invisible gas. Correct any leaks before driving!

©2004 Edelbrock Corporation
Catalog #5786

Page 1 of 2

Rev. 10/04

DA/mc

KIT CONTENTS

Catalog #5786

Qty. Part # Description Qty. Part # Description

❑ 1 25-3200 Downpipe assembly ❑ 1 25-3204 Tail pipe assembly
❑ 1 25-3201 I-pipe assembly ❑ 1 25-3205 Tail pipe extension
❑ 1 25-3202 I-pipe extension ❑ 1 25-5571 Muffler assembly
❑ 1 25-3203 Overaxle pipe assembly ❑ 1 22-5786 Installation kit hardware

©2004 Edelbrock Corporation
Catalog #5786

Edelbrock Corporation

2700 California St.

Torrance, CA 90503

Tech Line: [phone]

Office: [phone]

E-Mail: [e-mail]

Page 2 of 2

Rev. 10/04

DA/mc