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.