INSTRUCTIONS FOR KIT #405500
5” 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 1994-1998-1/2 models with
converter, but requires modifications to reinstall the original
converter. If originally equipped with a
converter, it
is illegal to use this vehicle on public roads with the converter
removed. NOTE:
for 1994-1998-1/2 models the tail pipe hangers may need to be
modified
or removed, and an alternate hanger setup installed.
NOTE: We highly recommend the use of a higher
flowing air filter or cold air kit, and a power programmer or high
performance
chip, for use with this exhaust system.
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 AND EXTENDED CAB SHOR BOX, YOU WILL NOT NEED THE
19” REAR
EXTENSION PIPE. ATTACH THE FRONT EXTENSION PIPE TO THE DOWN
PIPE USING
A 5” CLAMP.
4) USE A 5" CLAMP TO ATTACH THE 19” REAR
EXTENSION PIPE TO THE FRONT EXTENSION PIPE (FOR EXTENDED CAB LONG BOX
MODELS
ONLY, REGULAR CAB AND EXTENDED CAB SHORT BOX TRUCKS SKIP THIS STEP).
5) INSTALL THE MUFFLER TO THE EXTENSION PIPE
USING THE FRONT 5” HANGER CLAMP, ROTATE SLIGHTLY FOR CLEARANCE OF THE
FRAME AND
DRIVE SHAFT IF NECESSARY. NOTE: THE MUFFLER IS REVERSIBLE. 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.
6) INSTALL THE FRONT TAIL PIPE TO THE MUFFLER
USING A 5” CLAMP.
7) INSTALL THE MIDDLE 5” HANGER CLAMP TO THE
FRONT TAIL PIPE JUST AFTER THE FIRST BEND.
INSTALL THE WIRE HANGERS THAT ARE ON THE HANGER CLAMP TO THE
O.E. RUBBER
MOUNTS ABOVE.
8) INSTALL THE REAR TAIL PIPE TO THE FRONT TAIL
PIPE USING A 5” CLAMP. FOR THOSE WITHOUT
DUALLY MODELS, YOU WILL NEED TO TRIM THE REAR TAIL PIPE TO LENGTH.
9) INSTALL THE REAR 5” HANGER CLAMP TO THE REAR
TAIL PIPE JUST BELOW THE REAR O.E. RUBBER HANGER MOUNTS.
CONNECT THE WIRE PORTIONS OF THE HANGER TO
THE O.E. MOUNTS ABOVE. NOTE:
IF YOU HAVE A 1994-1998 MODEL YOU MAY NEED TO
MODIFY THE WIRE HANGERS TO FIT. EITHER
CUT AND RE-WELD OR INSTALL A BR91930 HANGER (OR EQUIVALENT, NOT
INCLUDED) TO
THE FRAME USING APPROPRIATE HARDWARE.
DRILL A HOLE IN THE FRAME IF NECESSARY IN A SUITABLE LOCATION. ATTACH THE HANGER TO THE TAIL PIPE USING A 5”
CLAMP (NOT INCLUDED). YOU MAY ALSO WELD
A HANGER ATTACHMENT TO THE TAIL PIPE, MAKE SURE IT IS RUBBER MOUNTED.
10) TIGHTEN ALL CLAMPS AND BOLTS AND CHECK FOR
CLEARANCE OF THE FRAME, BODY, AND BRAKE AND FUEL LINES.
HARDWARE
KIT FOR KIT
#4055500:
1) DOWN PIPE # 4055502
4)
5” CLAMPS # MC7500
1) FRONT EXTENSION PIPE # 4055503
1) FRONT 5” HANGER CLAMP # 2851
1) 19” REAR EXTENSION PIPE # 4055504
1)
MIDDLE 5” HANGER CLAMP # 2850
1) FRONT TAIL PIPE # 4055506
1) REAR 5” HANGER CLAMP # 2849
1) REAR TAIL PIPE # 4055507
1) OVAL MUFFLER 18” BODY
5”
Turbo Diesel Exhaust Kit
#4055500
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.