KIT #1005510  S/S ANGLE CUT TIPS    
        #1005520  PAINTED BLUNT TIPS
HEARTTHROB EXHAUST SYSTEMS ARE MANUFACTURED IN--LITCHFIELD, MN
DUAL EXHAUST KIT

FITS 1992-1993 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 2-3/4” ID/OD X 21” LONG EXTENSION PIPE AND A 2-3/4” 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 2-3/4” ID/OD EXTENSION PIPE (IF NECESSARY) TO THE CONVERTER PIPE USING A 2-3/4” CLAMP.  

3)  USE A 2-3/4"  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 2-3/4” 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)  2-3/4” CLAMPS                   
1)  LEFT TAIL PIPE (5 BENDS)
2)  FENDER WASHERS                   
1)  RIGHT TAIL PIPE (4 BENDS)
3)  THU900 (BR91930) 360 DEGREE SWINGER HANGER   
2)  MUFFLER TIPS    
2)  5/16" LOCK WASHERS               
1)  EXTENSION PIPE        
2)  5/16” X 1" BOLTS                        
2)  5/16" NUTS

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.