1025510
FITS FULL-SIZE 2002-2004 DODGE RAM W/3.7L V6, AND 4.7L & 5.9L V8,
ALL WHEEL BASES, BOTH 2WD & 4WD.
NOTE: DO NOT TIGHTEN ANY CLAMPS UNTIL THE LAST STEP!
1) REMOVE THE SPARE TIRE FROM UNDER THE TRUCK.
BECAUSE OF CLEARANCE
PROBLEMS, YOU WILL NOT BE ABLE TO RUN THIS SYSTEM WITH THE SPARE TIRE IN
ITS ORIGINAL POSITION. THEREFORE, IT MUST BE PULLED PERMANENTLY!!!
2) REMOVE EXHAUST SYSTEM AT THE CLAMP BEHIND THE
CONVERTER LEAVING ONLY THE ORIGINAL Y PIPE AND CATALYTIC CONVERTER ON
THE TRUCK.
3) THE 52” EXTENSION PIPE WILL FIT THE 160.5” WHEEL BASE TRUCKS
(QUAD CAB LONG BOX) WITHOUT
CUTTING. ON THE QUAD CAB SHORT BOX AND REGULAR CAB LONG BOX
(140.5” W.B.) THE EXTENSION PlPE WILL NEED TO BE CUT FROM THE 3" O.D.
END (THE END THAT IS NOT SHRUNK). CUT TO 33” ON THESE VEHICLES,
AND FOR REGULAR CAB SHORT BOX (120.5” W.B.) CUT TO 13”.
4) USE A 2-1/2" CLAMP TO ATTACH THE EXTENSION PIPE TO
THE CATALYTIC CONVERTER PIPE.
5) INSTALL THE MUFFLER TO THE EXTENSION PIPE USING
THE FRONT 3" HANGER CLAMP TO ATTACH THE MUFFLER (#6842 OR EQUIVALENT)
TO THE EXTENSION PIPE. INSTALL THE WIRE PORTION OF THE FRONT 3”
HANGER CLAMP TO THE O.E. RUBBER MOUNT ALONG SIDE THE EXHAUST SYSTEM.
6) INSTALL THE RIGHT TAIL PIPE TO THE MUFFLER.
USE THE RIGHT 3” HANGER CLAMP TO CONNECT THE MUFFLER AND THE RIGHT TAIL
PIPE. INSTALL THE WIRE PORTION OF THE RIGHT 3” HANGER CLAMP TO
THE O.E. RUBBER MOUNT ABOVE THE EXHAUST SYSTEM.
7) INSTALL THE LEFT TAIL PIPE TO THE MUFFLER. IT IS
ROUTED BETWEEN THE SHOCK AND WHERE THE
SPARE TIRE WOULD BE. USE THE LEFT 3” HANGER CLAMP TO CONNECT THE
MUFFLER AND THE LEFT TAIL
PIPE. INSTALL THE WIRE PORTION OF THE LEFT 3” HANGER CLAMP TO THE
O.E. RUBBER MOUNT ABOVE
THE EXHAUST SYSTEM.
8) INSTALL THE 3" I.D./O.D. TAIL PIPE
EXTENSIONS TO THE TAIL PIPES.
9) LOCATE MOUNTING HOLES IN THE FRAME NEAR THE END OF
THE OVER THE AXEL SECTIONS OF THE TAIL PIPES. THERE ARE TWO LARGE
1” WIDE HOLES THAT WILL SUFFICE. IF NO MOUNTING HOLES ARE PRESENT,
DRILL A 3/8" HOLE IN THE FRAME FOR EACH TAIL PIPE. INSTALL THE
BR91930 HANGERS USING THE LARGE AND FENDER WASHERS (INSTALL THE SMALLER
FENDER WASHER TO THE BOLT FIRST, THEN THE LARGER WASHER), NUTS, BOLTS
AND LOCK WASHERS. CLAMP THE HANGERS TO THE TAIL PIPES WHERE THEY
CONNECT TO THE TAIL PIPE EXTENSIONS, CONNECTING THE TWO PIPES AND THE
HANGERS, USING 3” CLAMPS. YOU MAY NEED TO BEND THE HANGERS AT 90
DEGREE ANGLES FOR PROPER FIT.
10) TRIM TAIL PlPES TO YOUR DESIRED LENGTHS.
11) TIGHTEN ALL CLAMPS AND NUTS AND BOLTS AND CHECK
FOR CLEARANCE OF BRAKE LINES AND CHASSIS COMPONENTS.
#1025510
HARDWARE
1) 2.50" CLAMP
1) FRONT EXTENSION PIPE
4) 3" CLAMPS
1) LEFT
TAIL PIPE
2) 3/8" LOCK WASHERS
1) RIGHT TAIL PIPE
2) 3/8" X 3-1/2" BOLTS
1) 6842 MUFFLER
2) 3/8" NUTS
2) TAIL
PIPE EXTENSIONS
2) #33012 ½” LARGE WASHERS
2) #33219 3/8” FENDER WASHERS
2) 360 SWINGER HANGER—BR91930
1) FRONT 3” HANGER CLAMP-#2910
1) LEFT 3” HANGER CLAMP-#2909
1) RIGHT 3” HANGER CLAMP-#2908
DANGER WARNING: Should the purchaser decide to install this, or any
other 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.
NOTES:
-THE LEFT TAIL PIPE HAS 6 BENDS--THE INLET IS THE
LONG END
-THE RIGHT TAIL PIPE HAS 5 BENDS--THE INLET IS THE
SHORT END
-THE MUFFLER OUTLETS SHOULD BOTH BE PARALLEL TO THE GROUND AND RUN SIDE
BY SIDE