INSTRUCTIONS FOR KIT #2002350 DUAL EXHAUST KIT
FITS 1996-1998 FULL-SIZE GM 1/2 & 3/4 TON 2WD & 4WD PICKUPS
W/5.7L 350 c.i. V-8 ONLY WITH THE FLANGE AND DUAL EXHAUST AT THE
CONVERTERS. THIS KIT FITS ALL WHEEL BASE MODELS.
NOTE: DO NOT TIGHTEN ANY CLAMPS OR FASTENERS UNTIL THE LAST STEP!
1) REMOVE THE OXYGEN SENSOR FROM THE TRUCK AND FROM THE LEFT
FLANGED FRONT PIPE, AFTER THE FLANGE AFTER THE CONVERTER. REMOVE
THE EXHAUST SYSTEM AT THE FLANGE BEHIND THE CONVERTERS LEAVING ONLY THE
ORIGINAL MANIFOLD PIPES, RUBBER MOUNTS FOR HANGERS, AND THE CATALYTIC
CONVERTERS ON THE TRUCK. YOU WILL NEED TO REUSE THE ORIGINAL NUTS
TO FASTEN THE FLANGE TO THE EXHAUST.
NOTE: THE INCLUDED FLANGED FRONT PIPE WILL NEED TO BE CUT TO FIT
THE REGULAR CAB AND EXTENDED CAB SHORT BOX MODELS. THIS PIPE FITS
EXTENDED CAB LONG BOX MODELS WITHOUT CUTTING. FOR EXTENDED CAB
SHORT BOX MODELS, CUT OFF APPROXIMATELY 14". REGULAR CAB
SHORT BOX CUT OFF APPROXIMATELY 38", AND CUT OFF 24" FOR REGULAR CAB
LONG BOX. TO AVOID PROBLEMS, PLEASE VERIFY THAT YOU ARE NOT
CUTTING OFF TOO MUCH BY PUTTING THE SYSTEM ROUGHLY IN PLACE AND DOUBLE
CHECKING THE LENGTHS BEFORE YOU DO ANY CUTTING!!!
2) INSTALL THE GASKET TO THE O.E. FLANGE AT THE CONVERTER.
INSTALL THE FLANGED FRONT PIPE TO THE GASKET AND O.E. FLANGE.
INSTALL THE NUTS TO THE BOLTS AT THE FLANGE BUT DON'T TIGHTEN
YET. YOU MAY INSTALL THE ORIGINAL OXYGEN SENSOR AT THIS
POINT.
3) INSTALL THE LONG 2-1/4" HANGER CLAMP TO THE RIGHT SIDE OF THE
FLANGED FRONT PIPE AT THE FRONT O.E. RUBBER MOUNT. CLAMP TO THE
PIPE AND SLIDE THE HANGER TO THE O.E. RUBBER MOUNT.
4) INSTALL THE MUFFLER TO THE FLANGED FRONT PIPE AND USE
2-1/4" MUFFLER CLAMPS TO ATTACH THE INLETS OF THE MUFFLER
(REVERSIBLE) AND THE FLANGED FRONT PIPE TOGETHER.
5) INSTALL THE RIGHT TAIL PIPE TO THE MUFFLER USING A 2-1/4"
CLAMP. INSTALL THE SHORT 2-1/4" HANGER CLAMP ON THE RIGHT TAIL
PIPE TO THE O.E. RUBBER MOUNT BEHIND THE REAR AXLE, AND CLAMP WITHIN
THE LAST BEND OF THE TAIL PIPE.
6) INSTALL THE LEFT TAIL PIPE TO THE MUFFLER USING A 2-1/4"
CLAMP. THE LEFT TAIL PIPE GOES UP OVER THE REAR DIFFERENTIAL AND
TO THE LEFT OF THE REAR SHOCK. INSTALL THE WELDED HANGER TO
THE LEFT TAIL PIPE USING A 2-1/4" CLAMP AND CONNECT TO THE O.E. RUBBER
MOUNT DIRECTLY BEHIND THE CONNECTING POINT OF THE MUFFLER AND THE LEFT
TAIL PIPE.
7) INSTALL THE BR91930 (360 DEGREE SWINGER HANGER) TO THE LEFT
TAIL PIPE AFTER THE REAR AXLE. 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 LEFT TAIL PIPE USING A 2-1/4" CLAMP.
8) INSTALL THE EXTENSIONS TO THE TAIL PIPES USING THE
2-1/4" CLAMPS. TRIM TO DESIRED LENGTH.
9) TIGHTEN THE THREE NUTS ON THE FLANGE AT THE CONVERTER, AND
TIGHTEN ALL CLAMPS AND BOLTS, AND CHECK THE OXYGEN SENSOR. CHECK
FOR CLEARANCE OF THE FRAME, BODY, AND BRAKE AND FUEL LINES.
HARDWARE KIT FOR KIT #2002350
1) FRONT FLANGED FRONT PIPE
1) FENDER WASHER
1) LEFT TAIL PIPE
1) #521039 GASKET
1) RIGHT TAIL PIPE
1) WELDED HANGER-#2942
1) MUFFLER #945
1) SHORT 2-1/4" HANGER CLAMP-#2907
2) TAIL PIPE EXTENSIONS
1) LONG 2-1/4" HANGER CLAMP-#2933
8) 2-1/4" CLAMPS
1) 360 SWINGER
HANGER--BR91930
1) 5/16"
LOCK WASHER
1) 5/16 X 1"
BOLT
1) 5/16"
NUT
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.
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.