INSTRUCTIONS FOR KIT #2005010 DUAL KIT
FITS 2002-2004 FULL-SIZE DODGE 1/2 TON RAM W/ 3.7L V6, 4.7L & 5.9L
V8, 2WD & 4WD, ALL WHEEL BASES, DOES NOT FIT DIESEL, AND V-10.
NOTE: DO NOT TIGHTEN ANY CLAMPS OR BOLTS UNTIL THE LAST STEP!
1) REMOVE THE EXHAUST SYSTEM AT THE CLAMP BEHIND THE CONVERTER
LEAVING ONLY THE ORIGINAL Y PIPE, RUBBER MOUNTS, AND CATALYTIC
CONVERTER ON THE TRUCK.
2) THE 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” FROM THE 3” O.D. END.
3) USE THE 2-1/2" CLAMP TO ATTACH THE EXTENSION PIPE TO THE
CONVERTER PIPE, BE SURE TO MATCH UP THE NOTCH.
4) SLIDE THE 3” HANGER CLAMP OVER THE EXTENSION PIPE.
ATTACH THE 3” HANGER CLAMP TO THE O.E. RUBBER MOUNT BESIDE THE
EXTENSION PIPE.
5) INSTALL THE MUFFLER. USE THE 3" MUFFLER CLAMP TO ATTACH
THE INLET OF THE MUFFLER AND THE EXTENSION PIPE TOGETHER.
6) INSTALL THE LEFT TAIL PIPE TO THE MUFFLER. IT HAS 3
BENDS AND THE SHORT END IS THE INLET (IT ALSO HAS A LESSER DEGREE OF
BEND ON THE INLET). THE LEFT TAIL PIPE RUNS BETWEEN THE SHOCK AND
THE FRAME.
7) INSTALL THE LEFT 2-1/4” HANGER CLAMP (SHORTER) TO THE
O.E. RUBBER MOUNT ABOVE THE LEFT TAIL PIPE JUST AFTER THE
MUFFLER. ATTACH THE LEFT 2-1/4” HANGER CLAMP TO THE
CONNECTING POINT OF THE LEFT TAIL PIPE AND MUFFLER.
8) LOCATE OR DRILL A HOLE IN THE FRAME NEAR THE END OF THE OVER
THE AXLE SECTION OF THE LEFT TAIL PIPE. (THERE IS A LARGE 1” HOLE
THAT IS IDEAL). USING THE 3/8” X 3-1/2" BOLT, NUT, LOCK,
AND LARGE AND FENDER WASHERS (install the smaller washer to the bolt
first, then the larger washer), INSTALL A BR91930 HANGER TO THE
FRAME AND ATTACH TO THE LEFT TAIL PIPE USING A 2-1/4" CLAMP. YOU
MAY NEED TO BEND THIS HANGER AT A 90 DEGREE ANGLE FOR PROPER FIT.
9) INSTALL THE RIGHT TAIL PIPE TO THE MUFFLER. IT HAS 5
BENDS AND THE SHORT END IS THE INLET. ATTACH THE RIGHT 2-1/4”
HANGER CLAMP (LONGER) TO THE O.E. RUBBER HANGER MOUNT ABOVE THE RIGHT
TAIL PIPE JUST AFTER THE MUFFLER. ATTACH THE RIGHT 2-1/4” HANGER
CLAMP TO THE CONNECTING POINT OF THE RIGHT TAIL PIPE AND MUFFLER.
10) LOCATE OR DRILL A HOLE IN THE FRAME NEAR THE END OF THE OVER
THE AXLE SECTION OF THE RIGHT TAIL PIPE. (THERE IS A LARGE 1”
HOLE THAT IS IDEAL). USING THE 3/8” X 3-1/2" BOLT, NUT,
LOCK, AND LARGE AND FENDER WASHERS (install the smaller washer to
the bolt first, then the larger washer), INSTALL A BR91930 HANGER TO
THE FRAME AND ATTACH TO THE RIGHT TAIL PIPE USING A 2-1/4" CLAMP.
YOU MAY NEED TO BEND THIS HANGER AT A 90 DEGREE ANGLE FOR PROPER FIT.
11) USING 2-1/4” CLAMPS, INSTALL AN I.D/O.D TAIL PIPE EXTENSION
TO THE LEFT AND RIGHT TAIL PIPES. (YOU WILL WANT TO TRIM THE
EXTENSIONS TO YOUR DESIRED LENGTH.)
12) TIGHTEN ALL CLAMPS AND BOLTS AND CHECK FOR CLEARANCE OF THE
FRAME, BODY, AND BRAKE AND FUEL LINES.
HARDWARE KIT FOR KIT #2005010:
1) FRONT EXTENSION PIPE 55” (SHRUNK)
1) LEFT TAIL PIPE
1) RIGHT TAIL PIPE
2) TAIL PIPE EXTENSIONS 30”
1) MUFFLER #907
1) 2-1/2” CLAMP
1) 3" CLAMP
1) 3” HANGER CLAMP-#2905
4) 2-1/4" CLAMPS
1) LEFT 2-1/4” HANGER CLAMP-#2904
2) (360 SWINGER HANGER)--BR91930
2) 3/8" X 3-1/2" BOLTS
2) 3/8" NUTS
2) #33012 1/2” LARGE WASHERS
2) #33219 3/8” FENDER WASHERS
2) 3/8" LOCK WASHERS
1) RIGHT 2-1/4” HANGER CLAMP-#2903
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.