INSTRUCTIONS FOR KIT #2009340                JCW # 50-5922      SINGLE EXHAUST KIT

FITS 1996-1999 FULL-SIZE GM 1/2 & 3/4 TON 2WD & 4WD SUBURBAN W/5.7L 350 c.i. V-8 WITH THE FLANGE AND DUAL EXHAUST AT THE CONVERTERS.  NOT FOR 8500+ GVW ¾ TON.

NOTE:  DO NOT TIGHTEN ANY CLAMPS OR FASTENERS UNTIL THE LAST STEP!

1)  REMOVE THE OXYGEN SENSOR FROM THE TRUCK AND FROM THE LEFT SIDE OF THE FLANGED FRONT PIPE 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.

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 WIRE HANGER ON THE FLANGED FRONT PIPE TO THE FRONT O.E. RUBBER HANGER MOUNT. 

4)  INSTALL THE MUFFLER TO THE FLANGED FRONT PIPE AND USE THE 2-1/4" MUFFLER CLAMPS TO ATTACH THE INLETS OF THE MUFFLER AND THE FLANGED FRONT PIPE TOGETHER. 

5)  INSTALL THE OVER THE AXLE SECTION OF THE TAIL PIPE TO THE MUFFLER USING A 3" CLAMP. 

6)  INSTALL THE FRONT HANGER CLAMP TO THE FRONT SECTION OF THE TAIL PIPE AT THE MIDDLE O.E. RUBBER HANGER MOUNT, AND CONNECT THE WIRE PORTION OF THE HANGER TO THE O.E. RUBBER HANGER MOUNT ABOVE. 

7)  INSTALL THE REAR SECTION OF THE TAIL PIPE USING THE REAR HANGER CLAMP TO CONNECT THE TWO PIPES.  INSTALL THE WIRE PORTION OF THE HANGER CLAMP TO THE O.E. RUBBER HANGER MOUNT ABOVE. 

8)  TIGHTEN THE THREE NUTS ON THE FLANGE AT THE CONVERTER, AND TIGHTEN ALL CLAMPS.  CHECK FOR CLEARANCE OF THE FRAME, BODY, AND BRAKE AND FUEL LINES, AND ALL CHASSIS COMPONENTS.  MAKE SURE THE OXYGEN SENSOR IS IN PLACE.

HARDWARE KIT FOR KIT #2009340, 50-5922:

1)  FRONT FLANGED FRONT PIPE-# 2009341                              1)  3" CLAMP

1)  REAR TAIL PIPE--# 2009343                                                        1)  #521039 GASKET

1)  MUFFLER #907 (DUAL 2-1/4”--SINGLE 3”)                              2)  2-1/4" CLAMP

1)  OVER THE AXLE TAIL PIPE--# 2009342                   1)  FRONT HANGER CLAMP--# 2865

                                                                                                                1)  REAR HANGER CLAMP--# 2937