Edelbrock 5787 Installation Instructions
©2007 Edelbrock Corporation
Catalog #5787
Brochure #63-0371
Rev. 2/07 - DA/mc
®
EDELBROCK DIESEL EXHAUST SYSTEM
for 2003-2007 Ford 6.0L
Crew Cab, Long & Short Bed
Catalog #5787
INSTALLATION INSTRUCTIONS
Please study these instructions carefully before installing your new Edelbrock Exhaust System. If you have any questions, contact
our Technical Hotline at: 1-800-416-8628 , 7am - 5pm, Monday-Friday, Pacific Standard Time or e-mail us at
Edelbrock@Edelbrock.com.
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 catalytic converter outlet.
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.
ASSEMBLY
1.
Install rear muffler hanger #23-4045 into factory
insulator.
2.
Extended cab models may require relocation of front
muffler frame mount 17” forward in frame in pre-drilled
holes. Install hanger #23-4052 onto muffler inlet (muffler
inlet is marked on nipple). Slip muffler into rear hanger
assembly and slide front hanger into isolators.
3.
Install overaxle pipe and slip into muffler.
4.
Install tailpipe hanger (#23-4046) into factory tailpipe
hanger insulator and slide onto the end of the overaxle
pipe.
5.
Install I-pipe onto catalytic converter outlet. Check length
of I-pipe, some models require cutting of the I-pipe.
Crew cab with short bed will require 15-1/2” be removed
from the outlet end of the I-pipe. Remember that I-pipe
slips over catalytic outlet and inside muffler. Measure
carefully before cutting pipe.
6.
Some models require different hanger types. Catalytic
converter clamps with hangers.
Use hanger
#23-4051. Some vehicles will use only a 3-1/2” U-clamp
(supplied) to attach the I-pipe to the outlet of the catalytic
converter.
Vehicles with a hanger in the mid-point
between catalytic converter and the muffler use hanger
#23-4053. Install the appropriate hangers and clamps for
I-pipe.
7.
Dual rear wheel applications require supplied tailpipe
extension (#25-3205). Install tailpipe (#25-3204) onto
overaxle and through tailpipe hanger clamp assembly.
8.
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.
9.
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!
Qty.
Part #
Description
❑ 1
25-3204
Tail pipe assembly
❑ 1
25-3198
I-pipe assembly
❑ 1
25-3205
Tail pipe extension
❑ 1
25-5571
Muffler assembly
❑ 1
25-3203
Overaxle pipe assembly
❑ 1
22-5787
Installation kit hardware
KIT CONTENTS
Edelbrock Corporation
2700 California St., Torrance, CA 90503
Tech Line: (800) 416-8628
E-Mail: Edelbrock@Edelbrock.com
INSTALLATION INSTRUCTIONS
IMPORTANT NOTE:
Proper installation is the responsibility of the installer. Improper installation will void warranty and may result in
poor performance and engine or vehicle damage.