KIT #1005010 S/S ANGLE CUT TIPS
#1005020 PAINTED BLUNT TIPS
HEARTTHROB EXHAUST SYSTEMS ARE MANUFACTURED IN--LITCHFIELD, MN
DUAL EXHAUST KIT
FITS 1990-1991 & 1994-1996 DODGE DAKOTA 2WD & 4WD PICKUPS
W/3.9L V-6 & 5.2L V-8 AND SINGLE 2-3/4" EXHAUST AFTER THE
CONVERTER. THIS KIT FITS ALL WHEEL BASE MODELS.
NOTE: DO NOT TIGHTEN ANY CLAMPS OR FASTENERS UNTIL THE LAST STEP!
NOTE: THE INCLUDED Y-PIPE IS A DIRECT REPLACEMENT OF THE
MUFFLER. CERTAIN MODELS HAVE THE CONVERTER PIPE EXTEND ALL THE
WAY TO THE MUFFLER. ON THESE VEHICLES, THE 2-1/2” ID/OD X 34”
LONG EXTENSION PIPE AND A 2-1/2” CLAMP WILL NOT BE NEEDED. IF
THERE IS AN EXTRA EXTENSION PIPE BETWEEN THE CONVERTER PIPE AND THE
MUFFLER, THIS EXTENSION PIPE AND CLAMP CAN BE USED IF YOU LIKE.
IF SO, YOU WILL NEED TO CUT TO THE SAME LENGTH AS THIS EXTENSION PIPE,
BUT BE SURE TO FIGURE IN THE 3” THAT WILL GO INTO THE Y-PIPE.
1) REMOVE THE EXHAUST SYSTEM AT THE CLAMP BEHIND THE CONVERTER
LEAVING THE O.E. CONVERTER AND FRONT Y-PIPE IN PLACE. REMOVE ALL
O.E. HANGER MOUNTS EXCEPT FOR THE O.E. HANGER THAT IS BETWEEN THE
MUFFLER AND THE CONVERTER (REMOVE THE TWO REAR HANGER MOUNTS ONLY).
2) CUT TO LENGTH AND INSTALL THE 2-1/2” ID/OD EXTENSION PIPE (IF
NECESSARY) TO THE CONVERTER PIPE USING A 2-1/2” CLAMP.
3) USE A 2-1/2" CLAMP TO ATTACH THE INLET OF THE Y PIPE AND
THE EXTENSION PIPE TOGETHER. FOR THOSE WITH AN O.E. HANGER
DIRECTLY ABOVE THE CONNECTING POINT OF THE Y-PIPE AND THE CONVERTER
PIPE OR EXTENSION PIPE (EXT. CAB 4X4), CONNECT THIS SAME 2-1/2” CLAMP
TO THE O.E. HANGER AND CLAMP TO THIS CONNECTING POINT.
4) REMOVE THE O.E. HANGER AT THE REAR OF THE Y-PIPE (IF YOU HAVE
NOT DONE SO ALREADY). YOU WILL NEED TO RE-USE THE LAG SCREW FROM
THIS PART. PUT A 90 DEGREE BEND IN A THU900 SWINGER HANGER IN THE
THIRD HOLE FROM THE END WITHOUT THE HOOK ON IT. USE THE LAG SCREW
FROM THE O.E. HANGER TO INSTALL THE THU900 HANGER TO THE SAME HOLE THAT
THE O.E. HANGER WAS MOUNTED TO.
5) INSTALL THE RIGHT TAIL PIPE TO THE Y PIPE USING A 2-1/4"
CLAMP.
6) INSTALL THE LEFT TAIL PIPE TO THE Y PIPE USING A 2-1/4"
CLAMP. THE LEFT TAIL PIPE GOES UP OVER THE REAR DIFFERENTIAL AND
BETWEEN THE SPARE TIRE AND THE SHOCK.
7) INSTALL A 2-1/4” CLAMP TO THE RIGHT TAIL PIPE TO CONNECT THE
THU900 HANGER INSTALLED IN STEP 4) AND THE RIGHT TAIL PIPE. IT
WILL BE PLACED IMMEDIATELY AFTER THE OTHER CLAMP.
8) INSTALL A THU900 (360 DEGREE SWINGER HANGER) TO THE LEFT AND
RIGHT TAIL PIPES AFTER THE REAR AXLE, BUT BEFORE THE TIPS. USE
THE BOLT, LOCK WASHER, FENDER WASHER AND NUT TO CONNECT THE SWINGER
HANGER TO THE FRAME. IF NO HOLE IS PRESENT, DRILL A 5/16" HOLE IN
THE FRAME. CONNECT THE SWINGER HANGER AND THE APPROPRIATE TAIL
PIPE USING A 2-1/4" CLAMP. YOU WILL NEED TO BEND THE HANGERS
SLIGHTLY TO GET THEM TO REACH THE TAIL PIPES.
9) HOLD UP A TIP TO A TAIL PIPE AT YOUR DESIRED EXIT
LOCATION. MARK THE TAIL PIPE (REMEMBER TO ACCOUNT FOR 3” OF THE
TAIL PIPE NEEDED TO GO INSIDE THE TIP) AND TRIM THE TAIL PIPE TO YOUR
DESIRED LENGTH. REPEAT FOR THE OTHER SIDE AND INSTALL THE TIPS TO
THE TAIL PIPES USING THE 2-1/4" CLAMPS.
10) TIGHTEN ALL CLAMPS AND BOLTS. CHECK FOR CLEARANCE OF
THE FRAME, BODY, CHASSIS AND BRAKE AND FUEL LINES.
7) 2-1/4" CLAMPS
1)
Y PIPE
2) 2-1/2” CLAMPS
1)
LEFT TAIL PIPE (5 BENDS)
2) FENDER WASHERS
1) RIGHT TAIL PIPE (4 BENDS)
2) MUFFLER TIPS
2) 5/16"
LOCK WASHERS
1) EXTENSION PIPE
2) 5/16 X 1"
BOLTS
2) 5/16" NUTS
3) THU900 (BR91930) 360
DEGREE SWINGER HANGER
DANGER WARNING: Should the purchaser decide to install this
exhaust product at home, be warned that pleasure car or light duty
truck/van “bumper” jacks are intended for emergency use only. The
use of frame contact jack stands in conjunction with a floor jack as
main support is highly recommended to minimize accidental dropping of a
vehicle while the installation proceeds.
Limitation of liability--Disclaimers: The regulation of emissions
production, noise levels and safety standards is undertaken by the
federal government, each of the fifty state legislatures, and by many
local municipalities, towns and counties.
The manufacturer makes no warranties of
merchantability, of fitness for a particular purpose, or that its
products are approved for general use, or that its products comply with
laws, regulations or ordinances in the states where they may be sold to
the ultimate purchaser, the consumer.
The entire risk as to the conformity of this product
in any such state and as to repair, should the product prove to be
defective or non-conforming, is on the retail purchaser, the buyer, the
ultimate consumer of such product and it is not upon the seller,
distributor, or manufacturer.
In this connection, retail purchaser, the buyer, the
ultimate consumer assumes the burden of the entire cost of any and all
necessary service, alterations, and or repair.
The foregoing statement limits the liability of the
manufacturer.