Issues with Magnaflow 15609 on 02 4X4??
 

I installed a Magnaflow 15609 on my 2002 FX4 and am having fit issues with the spare tire. I bought it from 4WheelParts. It arrived and the instructions said it was for 1997-2001, so I call 4Wheels and was asured this was the right system. I also called Magnaflow, just to be safe before cutting of the old exhaust.

Everything went fine up to the tailpipe. I had clearance issues, so I dropped the spare tire. But the exhaust hits the spare and I can not move the spare enough to the driver side to clear. I called Magnaflow ran thru the problem and they suggested sending pictures. I shot off the pictures and waited for a response... I called a couple of times and finally got the Tech I had spoken to in the morning. He looked at the pictures and said "Oh, we have fit issues with that system on the 4X4's because of the full size spare."???

He suggested taking it to an muffler shop and having them bend the exhaust tip down on their tubing bender. I was thinking I could cut some of the tail pipe at the muffler to shorted it, which would allow it slide forward and clear?

Has anyone else had this problem and how did you work around it?

When I added headers to one of my cars that had a Magnaflow catback, I abolustely had to cut about 2" off the intermediate to get it to fit, otherwise it was rattling like all hell.

If it looks like a shorter pipe would help, it's a pretty quick and easy thing to have done.

I have that same system on its way to me (should be delivered today) so I will let you know if I run into the same issues. Mine is a 2WD but I will let you know.

I installed the exact same system on my 02 4X4 screw yesterday and had to remove the spare as well. Did you decide to cut the tailpipe?

I had no issues installing it on mine.

Mine is a 2WD so do you think that could be the issue - smaller spare (235/70/16)?

P265/70R16's so I don't think tire size is the issue. Did you get the Magnaflow 15609?

I have not had a chance to cut it yet. I was trying to see if I could get by the Magnaflow offices to see if they had a better idea by looking at it in person before taking a saw to it.

The problem appears to be the 265/70 17 spare?

I purchased mine from Troyer Performance so I contacted them and they too directed me to Magnaflow. The reason they gave was that they had never seen this on an '02 before, '05's yes, but not '02. So I called Magnaflow and the guy I talked to said there was someone there that had the same kit on a 4X2 and it had "plenty" of clearance. So his suggestion was to get an RMA from Troyer and replace the whole unit. Back to Troyer I go and they are going to send a whole new kit as Magnaflow doesn't sell the parts seperately.

Other then that, I like the kit. It seems to have increased the giddy up factor and it sounds good too.

I will post more after the new kit arrives...

I installed a Magnaflo dual system on my 02 FX4, I have the full size spare, Had to trim the pipe a bit for it to fit around spare. I originally ordered the duals for out the back but they sent the side swept model, I decided to keep it instead of the hassel of returning it. Very happy with the system.

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had 1 on my 03 supercab 4x4- fit perfectly!

I have an 03 Supercrew Lariat with a 265/70 17 spare and it fits great. It took a little bit of adjustment from front of the truck on back to the rear but I was able to make it fit. I have about an inch of clearance between the pipe and the spare and the Chrome tip is about a 1/2 below the rear quarter panel. Good luck.

Yes, that is the one that I have on it.

OK, the replacement kit arrived and I finally got it installed. It definitely fits better, but there still is only approximately 1/4 to 1/2 inch clearance between tailpipe and the spare. I did have to make some adjustments before tightening it down to get the clearance and appearance I was looking for. That should be enough I think, but I would prefer more. So it appears the issue was with the tailpipe itself, either in one of the bends or where the hanger was welded, which I think is the most likely scenario.

Thanks go out to the folks at Troyer Performance for getting the new kit sent out!:beers: