3rd gen exhaust on 2nd gen “write up” with part #’s

Yes it works, a little work but nothing horrible. I was tired of waiting for the 2nd gen exhaust I ordered to arrive. So I picked up a nice take off locally for $100. Did this on my lunch break at work with a lift, it could be done in the ground though.

Step 1 was to cut the factory exhaust off right where it straightens out and take the old muffler/tailpipe off. You will reuse all the rubber isolators except the rear most one. Replace it with this;

Next cut the flange off your new 3rd gen exhaust, and mount the assembly onto the truck. Get it in place then mark and cut the original pipe leaving a half inch or so play for the clamp. Next use this clamp it’s the perfect size and much more heavy duty than the crap ones at chain auto stores.

Next mount them together and tighten the clamp, add your tip and you’re done!

 

Does it leak at the joint where the two pipes meet?

 

Nope it’s a pretty heavy duty clamp, tightened it down with an impact and checked with it running. No signs of leaking. You could always weld it too.

 

that clamp is what German cars come with.

it helps when installing them to clean the surface, lube it, and anti size or exhaust paste the bolts and finish with hand feel or torque spec.

 

Nope! They welded all the joints together!

 

Thank you for this idea!

I'm in the same boat (my oem muffler on my 2nd gen has rusted a hole in it) and find the 3rd Gen's are much easier and cheaper to source locally.

Did the muffler odd the 3.5l change any performance or noise characteristics when installed on a 4L?

 

No difference in performance or sound, except it’s much quieter now that it doesn’t have a hole in it.

 

Older thread, but how different is the flange between the exhausts?

 

I don’t remember, the 3rd gen exhaust was much shorter before the muffler. Not sure if the flange is further back or if it was from a different cab configuration.

 

Is the 3rd gen muffler physically smaller in anyway. I got some stuff goin on where the stock muffler will be in the way sense it is giant.

I just want it to sound like stock is my problem

 

Just did this this afternoon and wanted to say thanks for writing this up and thereby letting me know it was possible. I found a 3rd gen take off with 20k miles on craigslist for $50 and in the end the guy gave it to me. Cost me the clamp and the hanger and my truck is quiet.
Appreciate you taking the time to share the knowledge.