INSTRUCTIONS FOR # 1025560
FITS FULL-SIZE ½ TON 2004-2005 DODGE RAM W/5.7L V8 HEMI ONLY, ALL WHEEL BASES, BOTH 2WD & 4WD.
NOTE:  DO NOT TIGHTEN ANY CLAMPS UNTIL THE LAST STEP!

1)    REMOVE THE SPARE TIRE FROM UNDER THE TRUCK.  BECAUSE OF CLEARANCE
PROBLEMS, YOU WILL NOT BE ABLE TO RUN THIS SYSTEM WITH THE SPARE TIRE IN
ITS ORIGINAL POSITION.  THEREFORE, IT MUST BE PULLED PERMANENTLY!!!

2)    REMOVE EXHAUST SYSTEM AT THE CLAMP IN FRONT OF THE MUFFLER, LEAVING ONLY THE ORIGINAL Y PIPE AND CATALYTIC CONVERTER ON THE TRUCK.

3)  INSTALL THE FRONT EXTENSION PIPE TO THE CATALYTIC CONVERTER PIPE USING A 2-3/4” CLAMP.  THE 9” EXTENSION PIPE WILL FIT ALL WHEEL BASE TRUCKS WITHOUT CUTTING.

4)    INSTALL THE MUFFLER TO THE EXTENSION PIPE USING A 3" CLAMP TO ATTACH THE MUFFLER (#6842 OR EQUIVALENT) TO THE EXTENSION PIPE.

5)    INSTALL THE RIGHT TAIL PIPE TO THE MUFFLER.  USE THE RIGHT 3” HANGER CLAMP TO CONNECT THE MUFFLER AND THE RIGHT TAIL PIPE.  INSTALL THE WIRE PORTION OF THE RIGHT 3” HANGER CLAMP TO THE O.E. RUBBER MOUNT ABOVE THE EXHAUST SYSTEM.

6)   INSTALL THE LEFT TAIL PIPE TO THE MUFFLER.  IT IS ROUTED BETWEEN THE SHOCK AND
WHERE THE SPARE TIRE WOULD BE.  USE THE LEFT 3” HANGER CLAMP TO CONNECT THE
MUFFLER AND THE LEFT TAIL PIPE.  INSTALL THE WIRE PORTION OF THE LEFT 3” HANGER
CLAMP TO THE O.E. RUBBER MOUNT ABOVE THE EXHAUST SYSTEM.

7)    INSTALL THE 3" I.D./O.D.  TAIL PIPE EXTENSIONS TO THE TAIL PIPES.

8)    LOCATE MOUNTING HOLES IN THE FRAME NEAR THE END OF THE OVER THE AXLE SECTIONS OF THE TAIL PIPES.  THERE ARE TWO LARGE 1” WIDE HOLES THAT WILL SUFFICE. IF NO MOUNTING HOLES ARE PRESENT, DRILL A 3/8" HOLE IN THE FRAME FOR EACH TAIL PIPE.  INSTALL THE BR91930 HANGERS USING THE LARGE AND FENDER WASHERS (INSTALL THE SMALLER FENDER WASHER TO THE BOLT FIRST, THEN THE LARGER WASHER), NUTS, BOLTS AND LOCK WASHERS.  CLAMP THE HANGERS TO THE TAIL PIPES WHERE THEY CONNECT TO THE TAIL PIPE EXTENSIONS, CONNECTING THE TWO PIPES AND THE HANGERS, USING 3” CLAMPS.  YOU MAY NEED TO BEND THE HANGERS AT 90 DEGREE ANGLES FOR PROPER FIT.

9)    TRIM TAIL PlPES TO YOUR DESIRED LENGTHS.

10)    TIGHTEN ALL CLAMPS AND NUTS AND BOLTS AND CHECK FOR CLEARANCE OF BRAKE LINES AND CHASSIS COMPONENTS.

#1025520        

HARDWARE
4)    3" CLAMPS                                        1)  LEFT TAIL PIPE  
2)    3/8" LOCK WASHERS                    1)  RIGHT TAIL PIPE  
2)    3/8" X 3-1/2" BOLTS                        1)  6842 MUFFLER
2)    3/8" NUTS                                        2)  TAIL PIPE EXTENSIONS
2)    #33012 ½” LARGE WASHERS        1)  FRONT EXTENSION PIPE
2)    #33219 3/8” FENDER WASHERS
2)  360 SWINGER HANGER—BR91930
1)  LEFT 3” HANGER CLAMP-#2909
1)  RIGHT 3” HANGER CLAMP-#2908
1)  2-3/4" clamp




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.

NOTES:  
    -THE LEFT TAIL PIPE HAS 6 BENDS--THE INLET IS THE LONG END
    -THE RIGHT TAIL PIPE HAS 4 BENDS--THE INLET IS THE SHORT END
-THE MUFFLER OUTLETS SHOULD BOTH BE PARALLEL TO THE GROUND AND RUN SIDE BY SIDE