Author Topic: Replacing An 2003 F250 SD Diesel Exhaust System (Read 993 times)

submarinesailor · « **on:** October 29, 2011, 09:21:35 pm »

Well after 251,000 miles I need to replace the exhaust system, from the turbo back, on my 2003 F250 SD diesel. I was wondering if any of you have experience with MagaFlow “Polished Stainless Steel”replacement products. I'm thinking about replacing the OEM system with one from them. One of the things I was wondering about is weather to go with a 4” or 5” system. The 5” is about $180.00 dollars more. Here are some links to the packages I’m looking at: http://www.magnaflow.com/02product/shopexd.asp?zone=ALL&id=4010, http://www.magnaflow.com/02product/shopexd.asp?zone=ALL&id=4103.

Should I see an increase in fuel mileage due to reduced back pressure?

Having read thru the installations, one the thing concerns me, while installing the new tubing, you need to remove the transmission cross-member and lower it by 8” to “aid in the removal of the down pipe.” Will/could this damage the motor mounts?

Bruce

sprucebunny · « **Reply #1 on:** October 30, 2011, 06:19:41 am »

If it was me, I'd put a temporary support under the transmission and unbolt it from the crossmember.
Be gentle with the bolts on the trans. My truck ('00 F450 diesel manual trans) broke the mounting ears off the transmission housing. I'm still waiting for the garage to fix it. Guess they aren't looking forward to welding aluminum or whatever it's made of.

bill m · « **Reply #2 on:** October 30, 2011, 08:53:35 am »

sprucebunny, as for welding the transmission it needs to be removed and everything taken out of it so they can tig weld it. Tig welding can destroy the bearings if they are not removed.

sprucebunny · « **Reply #3 on:** October 30, 2011, 09:29:55 am »

Thanks, Bill. They plan on taking it out and it needs new bearings, too. Hope they remember to fix the exhaust at the same time.

Ironwood · « **Reply #4 on:** October 30, 2011, 09:09:05 pm »

I would opt for the larger diameter for the marginal increase in cost. I have not yet had to replace an exhaust on any of my diesels. Yes, it should help with backpressure and increase mileage, but you may need a "programmer/ chip" as well to compensate. I would lke to do both to my 02 7.3 but just can seem to find the $$$ right now. Try the FordTruckEnthusist site for ideas reccommendations. LOTS of good input on there by model and year.

Ironwood

jesse · « **Reply #5 on:** October 30, 2011, 10:05:35 pm »

i put a 4" magnaflow on a 2006 ford f250 i did not remove the transmission cross member i just cut the pipe in front of the cross member and cut the pipe behind the muffler to remove the old exhaust the 4" downpipe fits i do not think there is enough room to put a 5" downpipe in

Dale Hatfield · « **Reply #6 on:** October 31, 2011, 06:34:29 am »

I cant say what a 5 inch pipe sounds like in a ford. I have 2 doges with 5s . One has a muffler the other one does not . One without is LOUD , one with is still loud, I wont ever do it again.
I would ask around somebody near you should have one, ask for a test ride.Also ask with a 5 inch if you get to keep spare tire in the hanger ?

snowstorm · « **Reply #7 on:** October 31, 2011, 08:31:23 am »

5" on a little 6.0 ?? an N14 cummins would use 5" thats a 855ci engine yours is only 365ci. getting rid of the cat converter and a flow thru muffler should do it. look at a muffler off a big truck you can look stright thru it. a 6.0 in a f250 was 325hp thats 75 more than what IH used in there trucks. i think a tuner is asking for trouble. i have 2 7.3 and 2 6.0. just bought a f550 6.0 6 sp used it some with the snow we got went pretty well with 5yds of sand on it. loaded wt was around 23000. enpty wt with plow and MG combo sander dump is 13000

tyb525 · « **Reply #8 on:** October 31, 2011, 05:53:41 pm »

The show-off Ford diesels around here put all kinds of crazy muffler sizes on, not to mention ridiculous stacks. Tons of chips and such too. Course, I never see any of them doing any real work, just cruising around town blowing smoke (and $$$).

Dale Hatfield · « **Reply #9 on:** October 31, 2011, 08:13:46 pm »

Dont get me wrong. I live for diesel power. The only thing that runs on gas round here is the pushmower and chainsaws.
The 5 inch without muffler I built as a play toy 2 wheel much more power than stock. I however hate it when hooked to goosneck trailer when the sound is trapped.
The other 5 inch didnt have a muffler .It has a topper on it and the sound was trapped under the cap. 15 miles later im on the phone with muffler shop .

Ironwood · « **Reply #10 on:** October 31, 2011, 08:24:50 pm »

I ran a generic early aftermarket chip in my old 7.3 550 (called Super Chip). I kept it on the lowest setting foor fuel mileage. Changed the power band slightly for the better and gave a mile or two better in mileage. I mention it because running the stock chip may/may not work with the bigger exhaust. A chip spec'ed to your desires is the best way to go. Some "chip" folks want to know how you use the truck and can program the chip they sell you accordingly, one brand called Five Star does just this, I am sure others can do the same. I dont chip like the crazy hot rod kids do, I do it so the truck will perform my work tasks better. I also dont want to have to buy a bunch of gauges to monitor things, just give me the best options without getting too crazy.

Ironwood

Bobus2003 · « **Reply #11 on:** November 01, 2011, 06:14:50 pm »

I ran a 5" straight pipe exhaust on my '99 F250 7.3l. had the biggest Down pipe I could get, think it was a 4" and it went in with a bit of help, Didn't have to remove or loosen any thing on the truck to get it in. Biggest complaint i have against 5" exhaust is the drone that occurred when towing. Has a good throaty sound with a nice turbo whistle when running empty truck. I was running a 80hp Superchip (Now i run TS 6 position chip in my 7.3l, or use SCT in the 6.0l, Way better tuning capabilities) saw 21-22mpg running empty and being nice to it, and was in the mid teens pulling a GN trailer and skid steer.. Worst i ever got was 8mpg running about 80, pulling a GN trailer with a pair of firetrucks to Eastern Nebraska.

On my '06 6.0l I ran a 4" straight pipe exhaust, had a neat sound, no issues with the install, didn't really see any gains in mpg or power just made more noise

Best way to make a improvement is do the exhaust and an air intake.. I home made mine on my 7.3l

snowstorm · « **Reply #12 on:** November 03, 2011, 06:01:00 pm »

have any of you 6.0 owners replaced the up pipe or is it down pipe? on the right side of the motor. how tuff of a job is it?

LeeB · « **Reply #13 on:** November 04, 2011, 09:10:54 am »

In my humble opinion, I think it would be best to replace it with an exaust system off a Dodge. Seeing as how that won't fit, you should then replace the Ford part of the equation with the rest of the Dodge.

Bobus2003 · « **Reply #14 on:** November 04, 2011, 09:15:10 pm »

Quote from: snowstorm on November 03, 2011, 06:01:00 pm

have any of you 6.0 owners replaced the up pipe or is it down pipe? on the right side of the motor. how tuff of a job is it?

So which is it? Up-Pipe or the Down-Pipe? When you say Right side are you looking at the truck or Right as in Passenger side? Up-Pipes arn't too bad to do if you have a few hours of time. I know many guys that have jacked the cab to do exhaust and head work on 6.0l's.. The Down-Pipe is easy, just undo the clamps and wiggle it out the bottom, then re-install new DP up from the bottom

snowstorm · « **Reply #15 on:** November 05, 2011, 08:03:10 am »

yes its the up pipe right side. ford dealer gave me a price of $1700 to replace the up pipe. seems a little high. i have a egr delete kit coming

submarinesailor · « **Reply #16 on:** November 23, 2011, 03:00:52 pm »

Well I finally got around to finishing the bedroom painting and flooring so I can get back to this problem/task.

I found what I was looking for a one of the web sites, a MagnaFlow discounter. But, I wanted to make sure I was ordering the exactly right system/parts. So, I called MagnaFlow and asked. Much to my surprise, I was inforned that they did not make one "yet" that fits my truck.

A 2003 F250 extended cab with the short bed. @#$%^& So, I started looking else where. Hopefully, I have found what I need with Banks Power. That's a name I remember being around for a long time. Their web site was very clear, whereas MagnaFlow's wasn't. My confort zone is up a littler more. But, I will still call them just to make sure. Well let you guys know what is happening as I get this - hopefully anyways.

Bruce

jesse · « **Reply #17 on:** November 25, 2011, 01:41:42 pm »

picture of magnaflow on 2006 f250 short bed extended cab

after picture

before picture

snowstorm · « **Reply #18 on:** November 25, 2011, 06:22:12 pm »

my 6.0 is almost back together. 04 with 60k 3 broken exhaust manifold bolts bolt exhaust manifolds were rusted so bad where the pipe bolts on had to be replaced. also a leak between the intake and exhaust side of the turbo and the egr cooler was leaking antifreeze into the intake.

Bobus2003 · « **Reply #19 on:** November 26, 2011, 11:57:18 am »

MBRP makes a good system for the big three diesel trucks.. Banks is way over priced IMHO.

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Author Topic: Replacing An 2003 F250 SD Diesel Exhaust System (Read 993 times)