INSTRUCTIONS FOR 5” DIESEL KIT TURBO-BACK KIT     #4055770

FITS: 2001-2004 FULL-SIZE GM DURAMAX 3/4 & 1 TON W/6.6L TURBO DIESEL, 2WD & 4WD, EXTENDED CAB MODELS (short bed = 143.5”, long bed  = 157.5” wheel bases), THIS IS A TURBO-BACK KIT.  NOTE:  this system is not designed for on-road use on vehicles with a catalytic converter.

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

NOTE:  WE HIGHLY RECOMMEND THE USE OF A HIGER FLOWING AIR FILTER OR COLD AIR KIT, AND A POWER PROGRAMMER OR HIGHER PERFORMANCE CHIP, FOR USE WITH THIS EXHAUST SYSTEM. 

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.  DISCONNECT THE BOLTS AT THE FLANGE AT THE REAR OF THE O.E. DOWN PIPE.  YOU MAY NEED TO CUT YOUR ORIGINAL SYSTEM APART TO REMOVE IT MORE EASILY FROM THE VEHICLE.  YOU WILL NEED TO RE-USE THE ORIGINAL V-BAND CLAMP AT THE TURBO. 

2)  INSTALL THE DOWN PIPE TO THE TURBO AND INSTALL THE ORIGINAL V-BAND CLAMP.  TIGHTEN ONLY ENOUGH TO HOLD IN PLACE.  INSTALL THE WIRE HANGER ON THE DOWN PIPE TO THE O.E. RUBBER MOUNT BELOW THE WIRE HANGER.

3)  INSTALL THE FRONT EXTENSION PIPE TO THE DOWN PIPE USING A 5” CLAMP.  IT IS THE EXTENSION PIPE WITH 3 BENDS IN IT, ID END IS THE INLET.  THE EXTENSION PIPE IS BENT TO CLEAR THE CROSS MEMBER.  ROTATE AS NECESSARY FOR CLEARANCE.  USE THE 5” FRONT HANGER CLAMP TO ATTACH THE FRONT EXTENSION PIPE TO THE O.E. HANGER JUST AFTER THE SECOND BEND IN THE FRONT EXTENSION PIPE.  ATTACH THE CLAMP PORTION TO THE FRONT EXTENSION PIPE, AND THE WIRE PORTION TO THE O.E. RUBBER HANGER MOUNT ALONG THE SIDE OF THE PIPE.

4)  THE MIDDLE EXTENSION PIPE WILL FIT THE EXTENDED CAB LONG BOX MODELS.  ON THE SHORT BOX MODELS, YOU WILL NOT NEED THIS 17” ID/OD EXTENSION PIPE.  USE A 5” CLAMP TO CONNECT THE MIDDLE AND FRONT EXTENSION PIPES (IF NECESSARY). 

5)  INSTALL THE MUFFLER TO THE EXTENSION PIPE USING A 5” CLAMP.  NOTE:  THE MUFFLER is reversible, you may need to rotate for clearance of the frame and drive shaft.  INSTALL THE WIRE PORTION OF THE HANGER TO THE O.E. RUBBER HANGER MOUNT ABOVE.

6)  INSTALL THE FRONT TAIL PIPE TO THE MUFFLER USING THE 5” MIDDLE HANGER CLAMP (SEE DRAWING) AT THE CONNECTING POINT OF THE FRONT TAIL PIPE AND MUFFLER.  INSTALL THE WIRE HANGER THAT IS ON THE HANGER CLAMP TO THE O.E. RUBBER MOUNT ABOVE. 

7)  INSTALL THE REAR TAIL PIPE TO THE FRONT TAIL PIPE USING A 5” CLAMP. 

8)  INSTALL THE 5” REAR HANGER CLAMP TO THE REAR TAIL PIPE BEFORE THE LAST BEND AND BELOW THE O.E. RUBBER HANGER MOUNT.  INSTALL THE WIRE PORTION OF THE HANGER TO THE O.E. MOUNT ABOVE.

9)  FOR THOSE WITHOUT DUALLY MODELS, YOU WILL NEED TO TRIM THE REAR TAIL PIPE TO LENGTH. 

10)  TIGHTEN ALL CLAMPS AND THE V-BAND CLAMP AT THE TURB O, AND CHECK FOR CLEARANCE OF THE FRAME, BODY, CHASSIS COMPONENTS, AND BRAKE AND FUEL LINES.

HARDWARE KIT FOR KIT #4055770:

1)  DOWN PIPE # 4055751                                  4)  5” CLAMPS #MC7500

1)  FRONT EXTENSION PIPE # 4055771                         1)  5” FRONT HANGER CLAMP # 2833

1)  17” MIDDLE EXTENSION PIPE # 4055753                1)  5” REAR HANGER CLAMP # 2846

1)  OVAL MUFFLER SHORT BODY 14”                         1)  5” MIDDLE HANGER CLAMP # 2847

1)  FRONT TAIL PIPE # 4055506                                      

1)  REAR TAIL PIPE # 4055507