INSTRUCTIONS FOR KIT #4005500    4” DIESEL KIT TURBO-BACK KIT 

FITS: 1994-2002 FULL-SIZE DODGE 3/4 & 1 TON RAM W/5.9L SIX CYLINDER TURBO DIESEL, 2WD & 4WD, ALL WHEEL BASES, THIS IS A TURBO-BACK EXHAUST KIT, FOR VEHICLES WITHOUT CATALYTIC CONVERTER.  

NOTE:  THIS KIT ALSO FITS 1994-1998 MODELS WITH CONVERTER, BUT REQUIRES MODIFICATIONS TO RE-INSTALL THE ORIGINAL CONVERTER.  IF ORIGINALLY EQUIPPED WITH A CATALYTIC CONVERTER, IT IS ILLEGAL TO USE THE VEHICLE ON PUBLIC ROADS WITH THE CONVERTER REMOVED.  NOTE:  FOR 1994-1998 MODELS THE TAIL PIPE HANGERS MAY NEED TO BE MODIFIED OR REMOVED, AND AN ALTERNATE HANGER SETUP INSTALLED.

NOTE:  DO NOT TIGHTEN ANY CLAMPS OR BOLTS UNTIL THE LAST STEP!  READ THESE INSTRUCTIONS FULLY AND THOROUGHLY BEFORE YOU BEGIN.

1)  REMOVE THE EXHAUST SYSTEM AT THE FLANGE AT THE TURBO (USING AN M15 EXTENDED SOCKET).  REMOVE THE WIRE HANGERS FROM THE O.E. RUBBER HANGER MOUNTS (A LUBRICANT MAY BE NECESSARY), BUT LEAVE THESE RUBBER HANGER MOUNTS ON THE TRUCK.  DISCONNECT THE CLAMPS AT THE REAR OF THE O.E. DOWN PIPE AND AT THE INLET OF THE MUFFLER.  YOU WILL NEED TO RE-USE THE ORIGINAL NUTS AND BOLTS AT THE TURBO FLANGE.  

2)  INSTALL THE DOWN PIPE TO THE FLANGE AT THE TURBO AND INSTALL THE ORIGINAL NUTS AND BOLTS.  TIGHTEN ONLY ENOUGH TO HOLD IN PLACE.  INSTALL THE WIRE HANGER THAT IS ON THE DOWN PIPE TO THE O.E. RUBBER MOUNT ON THE DRIVER’S SIDE OF THE PIPE.

3)  BOTH OF THE EXTENSION PIPES WILL FIT THE EXTENDED CAB LONG BOX MODELS WITHOUT CUTTING.  ON THE REGULAR CAB MODEL, YOU WILL NOT NEED THE 26” (SHORTER) EXTENSION PIPE.

4)  USE THE 4" CLAMP TO ATTACH THE 26” EXTENSION PIPE TO THE DOWN PIPE (FOR EXTENDED CAB MODELS ONLY, REGULAR CAB TRUCKS SKIP THIS STEP).

5)  ATTACH THE 39” EXTENSION PIPE (CUT TO LENGTH IF NECESSARY) TO THE SHORTER 4” EXTENSION PIPE USING A 4” CLAMP.  

6)  INSTALL THE MUFFLER TO THE EXTENSION PIPE USING THE FRONT 4” HANGER CLAMP.  NOTE:  THE EXHAUST SHOULD FLOW OVER, AND NOT DIRECTLY INTO, THE LOUVERS OF THE MUFFLER.  CONNECT THE LONGER WIRE HANGER TO THE DRIVER’S SIDE RUBBER MOUNT, AND THE SHORTER WIRE HANGER TO THE PASSENGER SIDE RUBBER MOUNT, BOTH ABOVE THE CONNECTING POINT OF THE EXTENSION PIPE AND THE MUFFLER.

7)  INSTALL THE TAIL PIPE TO THE MUFFLER USING THE REAR 4” HANGER CLAMP.  INSTALL THE WIRE HANGERS THAT ARE ON THE HANGER CLAMP TO THE O.E. RUBBER MOUNTS ABOVE.  INSTALL THE WIRE PORTION OF THE HANGERS ON THE TAIL PIPE TO THE O.E. RUBBER MOUNTS ABOVE THE HANGERS.  

8)  FOR THOSE WITH DUALLY MODELS, YOU WILL NEED TO INSTALL THE TAIL PIPE EXTENSION TO THE TAIL PIPE USING BY EITHER WELDING (RECOMMENDED FOR APPEARANCE REASONS) OR USING A 4” CLAMP (INCLUDED).  YOU MAY NEED TO TRIM TO LENGTH AND STYLE OF CUT.

9)  TIGHTEN ALL CLAMPS AND BOLTS AND CHECK FOR CLEARANCE OF THE FRAME, BODY, AND BRAKE AND FUEL LINES.

HARDWARE KIT FOR KIT #4005500
1)  DOWN PIPE # 4005502           
3)  4” CLAMPS # MC7400
1)  26” FRONT EXTENSION PIPE # 4005503   
1)  FRONT 4” HANGER CLAMP # 2979
1)  39” REAR EXTENSION PIPE # 4005504   
1)  REAR 4” HANGER CLAMP # 2978
1)  TAIL PIPE # 4005506                
1)  TAIL PIPE EXTENSION # 4005507        
1)  MUFFLER #5024-114AL            

INSTRUCTIONS FOR KIT #4005500    4” DIESEL KIT TURBO-BACK KIT 

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.
 
FOR DETAILED DIGITAL PICTURES OF THIS SYSTEM INSTALLED EMAIL US AT:  HEARTTHROB@WILLMAR.COM