This weekend I installed my new Magnaflow 15609 cat back exhaust on my 2003 F150 Supercab Flareside. When I opened the box I was very impressed with the quality of the system. After installation I was satisfied with the sound of the system as I did not want anything too loud. I did have a few installation problems and was wondering if others with this system had the same issues and how they resolved them.

First, I could not get the front clamp to tighten up enough to secure the pipe to the 2 1/2" "Y" pipe. The u-bolt in the stainless clamp just snapped off before it got tight enough. I had to go to a local auto parts store and buy a heavy duty clamp (regular steel). The other two clamps on each side of the muffler did tighten up but the nuts are galled up and will break if tightened or loosed.

Second, and the problem I am mainly concerned with, is the clearance between the tail pipe and the spare tire and the factory installed mud flaps. I adjusted and reposition the tail pipe many times before I got any clearance with these items. If I cleared the spare it hit the mud flap. If I cleared the mud flap it hit the spare. I finally let the spare down some and shifted it over in the carrier and split the difference as best as I could. I have 1/2" to 3/4" at each. This does not seem to be enough to me. I am afraid the heat from the tail pipe will melt the plastic mud flap or damage the rubber on the spare.

I plan on calling Magnaflow Monday to discuss this problem and see if they have a solution. Has anyone else had this clearance problem with the Magnaflow 15609 system? If so, how did you fix it?

Thanks for your input.
James

 

I put the 15609 on my SCREW.

I don't have mudflaps, so I can't speak to that problem.

My clamps tightened up just fine, but after a few days I decided to tighten them a bit more, and I snapped one. I believe stainless clamps are more brittle than the hardened steel.

I positioned my tailpipe closer (about 1/4 in of clearance ) to the plastic rock guard than they said to (that way it aims straight out and isn't angled down), and haven't had any heat/melting/discoloration issues with the plastic.

Remember the double wall construction of the tailpipe means it is much cooler than a single wall would be. Just don't let it touch the plastic.

Also, it will get considerably(IMO) louder when it finally breaks in.

 

those brackets suck, i did the same as you both, snap one then make a trip to the auto store, also i had to lower the spare tire to get the damn thing from rubbing, obviously an error on magnaflow design


semper fi

 

i installed my 15749 yesterday. i had no problems with the clamps but the instructions called for the hangers they sent to be bolted into existing holes in the frame... which i think my reece hitch was using. they didn't mention that. they also hang really low, about 3"-4" below the bumper and everyone elses are right up next to it. i have several issues. i think i may have been better off having a shop do it. anyway my .02 to your questions about magnaflow install problems.

 

I contacted Magnaflow tech support and was told that there was only one tail pipe configuration for the 15609 system. The system is designed to fit different cab/bed combinations. If I didn't have the factory mud flaps on the Flairside box, I could have shifted the tail pipe to miss the spare tire more. When I get the time I am going to a local muffler shop and let them adjust the tail pipe to miss the spare and the mud flap. Right now I have the spare tire shifted away from, and toward the rear of the truck.

The Magnaflow tech also told me that the stainless steel clamps were not as strong as regular steel. He said that everyone wanted a full stainless steel exhaust system, even the clamps, and that was one of the compromises. He suggested that I go get some heavy duty regular steel clamps. I went to AutoZone and bought some. I was able to get the joints good and tight with the steel clamps.

All in all I am pleased with the Magnaflow system. Everything is high quality materials and workmanship. It's almost a shame to put the beautiful, highly polished muffler under the truck where you can't see it! It sounds great! No droning in the cab when cruising at highway speeds. It has a nice deep throaty sound when under acceleration. Great V8 sound!

When I get the tail pipe adjusted, I will be 100% happy with it. Also, you can't beat the lifetime warranty.

 

Did you do the install yourself. Is it just a matter of unbolt and bolt on the new one, or is a blow torch required?

 

15609 and 15749 are bolt on kits. No welding required. Now for my 15749 i needed to cut the mid pipe right behind the muffler per the instructions. Also the mid pipe would not slide off the cat conv because the factory clamp and bent the pipe around it. I had to use a grinder to cut it down the middle to get it off. Other that it was pure bolt on kit.

A warning though, if you go with the SI/DO 15749, the hangers they gave me did not have anywhere to go because of my factory tow pckg.

looks and sounds great though!

 

Have any of you installed this system on a regular cab pickup?
I understand it is designed for an extended cab truck. If so what modifications were required. Was it as simple as shortening the pipe in front of the muffler to the correct length? Thanks in advance for any replies you may have.