Gibson 9522, 69522 Instruction Manual

INSTRUCTION MANUAL

CAT-BACK EXTREME DUAL EXHAUST SYSTEM

99-02 FORD EXPEDITION/NAVIGATOR 4.6L-5.4L 2/4WD

PART # 9522

CATALYTIC A B I D F
CONVERTER

E
G

E

G H G C G,J,K F

ITEM PART # QUANTITY DESCRIPTION

A 700176 1 3” HEADPIPE
B 758250 1 SUPERFLOW MUFFLER
C 700585 1 2-1/2” DRIVERSIDE TAILPIPE
D 700586 1 2-1/2” PASSENGER SIDE TAILPIPE
E 700587 2 2-1/2” EXIT PIPES
F 500396 2 3-1/2” STAINLESS TIP
G 5757 4 2-1/2” CLAMP
H OHD300 1 3” CLAMP
I 40083 1 REAR MUFFLER HANGER
J 08269 1 10” METAL HANGER
K BO-101 1 BOLT KIT FOR 10” HANGER
L ZIP 2 ZIP TIE

Thank you for purchasing our Gibson exhaust system for your vehicle. If you need further
assistance, please do not hesitate to call our technical dept at [phone] Monday
through Friday, 8:00 am to 5:00 pm. 0206

EXHAUST INSTALLATION PART # 9522

WHEN INSTALLING THIS EXHAUST SYSTEM ,MAKE SURE TO USE PROPER SAFETY
PRECAUTIONS.USE JACK STANDS WHEN UNDER THE TRUCK, SET PARKING BRAKE, BLOCK TIRES
AND USE SAFETY GLASSES AND GLOVES. DO NOT WORK WITH HOT PIPES!

SUGGESTED TOOLS

9/16 “, ½”, 15 MM WRENCH AND SOCKET, WD-40, HACKSAW OR SAWZALL, JACKSTAND

Lay out the exhaust on the floor
so it looks like the drawing and
compare parts with manual. To

remove the stock exhaust, un­clamp it just in front of the
muffler. You may need to heat it

up for easier removal. Leave all
rubber grommets in place. Use
WD-40 to aid in removal of
exhaust and the hangers. Now cut
off your stock tailpipe just behind
the muffler.

Install head pipe #A onto your
existing stock front pipe and
secure with clamp # G. Use a
jack stand to support the
converter. Do not tighten.

Install muffler #B onto head
pipe 1 ½” to 2” with the louvers
facing towards the converter.
Use a jack stand to support
the muffler. Use clamp # H to
secure the muffler to the head
pipe. Do not tighten. Outlets
should be on the bottom.

Measure approx. 12” from
the rear of the frame
and use the bolt that is
there, and install 10”
hanger # J use the 3
hole on the hanger and
install re-using the
factory nut.

Next, install drivers side
tailpipe # C into muffler
1-1/2” to 2” route between
spare tire and shocks use
clamp # G to secure, do not
tighten.

Install passenger side
tailpipe # D into muffler
1-1/2” to 2”, use clamp # I
to secure. Do not tighten.
Slide welded hanger into
rubber grommet.

Install exit pipes # E onto
tailpipes, and rotate until
level.

rd

Install rear mufflerT­hanger # I into rubber
grommets located just
above the muffler outlets.
Shorter side of the hanger
will be inserted on the
passenger side grommet.
Slide clamp onto passenger
side muffler outlet. Do not

MAKE SURE YOU HAVE A 1” CLEARNACE ON

ALL RUBBER BRAKE LINES, SHOCK BOOTS,

TIRE, FUEL LINES, ETC…

Install your stainless tips
to your desired look, then
go back tighten all clamps
from the front working
your way back.