INSTRUCTIONS FOR KIT #4005520           4” DIESEL KIT TURBO-BACK KIT          

FITS: 2003-2004 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:  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 V-BAND CLAMP AT THE TURBO.  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.

2)  INSTALL THE DOWN PIPE TO THE TURBO USING THE ORIGINAL V-BAND CLAMP.  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 CREW CAB LONG BOX MODELS (160.5” W.B.).  ON THE REGULAR CAB LONG BOX AND CREW CAB SHORT BOX MODELS (140.5” W.B.), YOU WILL NOT NEED THE 23” (SHORTER) EXTENSION PIPE.

4)  USE A 4" CLAMP TO ATTACH THE I.D. INLET OF THE 45” EXTENSION PIPE TO THE DOWN PIPE.

5)  FOR CREW CAB LONG BOX MODELS ONLY, ATTACH THE I.D. INLET OF THE 23” EXTENSION PIPE TO THE 45” EXTENSION PIPE USING A 4” CLAMP. 

6)  INSTALL THE MUFFLER TO THE APPLICABLE EXTENSION PIPE USING THE FRONT 4” HANGER CLAMP.  NOTE:  THE EXHAUST SHOULD FLOW OVER, AND NOT DIRECTLY INTO, THE LOUVERS OF THE MUFFLER.  INSTALL THE WIRE PORTION OF THIS HANGER TO THE O.E. RUBBER HANGER MOUNT THAT IS ABOVE AND FORWARD OF THE INLET OF THE MUFFLER.  NOTE:  ON THE CREW CAB LONG BOX MODELS THERE IS ANOTHER O.E. HANGER IN FRONT OF THIS MOUNT THAT IS NOT USED FOR THIS KIT. 

7)  INSTALL THE TAIL PIPE TO THE MUFFLER USING THE MIDDLE 4” HANGER CLAMP.  INSTALL THE WIRE HANGER THAT IS ON THE HANGER CLAMP TO THE O.E. RUBBER MOUNT ABOVE ON THE SIDE THAT IS NEAREST TO THE DRIVESHAFT.  THERE IS ANOTHER O.E. HANGER ON THE OPPOSITE SIDE OF THE HANGER NEAREST TO THE DRIVESHAFT THAT IS NOT USED IN THIS KIT.

8)  INSTALL THE REAR 4” HANGER CLAMP TO THE TAIL PIPE BEFORE THE LAST BEND AND JUST BELOW THE O.E. RUBBER HANGER MOUNT JUST BEHIND THE REAR AXLE.  CONNECT THE WIRE PORTION OF THE HANGER CLAMP TO  THE O.E. RUBBER HANGER MOUNT ABOVE.

9)  FOR THOSE WITH DUALLY MODELS, YOU WILL NEED TO INSTALL THE I.D. INLET OF 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.

10)  TIGHTEN ALL CLAMPS, BOLTS, AND THE V-BAND CLAMP AT THE TURBO, AND CHECK FOR CLEARANCE OF THE FRAME, BODY, AND BRAKE AND FUEL LINES.

HARDWARE KIT FOR KIT #4005520:

1)  DOWN PIPE # 4005521                                  3)  4” CLAMPS # MC7400

1)  45” FRONT EXTENSION PIPE # 4005522  1)  FRONT 4” HANGER CLAMP # 2874

1)  23” REAR EXTENSION PIPE # 4005523     1)  REAR 4” HANGER CLAMP #2872

1)  TAIL PIPE # 4005506                                                     1)  MIDDLE 4” HANGER CLAMP # 2873

1)  TAIL PIPE EXTENSION # 4005507                            

1)  MUFFLER #5024-114AL                                              

INSTRUCTIONS FOR KIT #4005520           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