INSTRUCTIONS FOR KIT #4055525    5” DIESEL KIT CAT-BACK KIT    #

FITS: 2004-1/2  FULL-SIZE DODGE 3/4 & 1 TON RAM W/5.9L SIX CYLINDER TURBO DIESEL, 2WD & 4WD, ALL WHEEL BASES, THIS IS A CAT-BACK EXHAUST KIT, FOR VEHICLES WITH 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 CLAMP AFTER THE CONVERTER.  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)  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” (LONGER) EXTENSION PIPE.  FOR ALL WHEEL BASES, USE A 4” CLAMP TO ATTACH THE 4” I.D. END OF THE FRONT EXTENSION PIPE TO THE CONVERTER PIPE.

3)  FOR THOSE WITH THE 160.5” WHEEL BASE (CREW CAB LONG BED), USE A 5" CLAMP TO ATTACH THE I.D. INLET OF THE MIDDLE EXTENSION PIPE TO THE FRONT EXTENSION PIPE.

4)  INSTALL THE MUFFLER TO THE APPLICABLE EXTENSION PIPE USING THE FRONT 5” HANGER CLAMP.  NOTE:  THE MUFFLER IS REVERSIBLE, AND YOU WILL NEED TO INSTALL IT IN A COCKED POSITION FOR CLEARANCE OF THE FRAME AND THE DRIVE SHAFT.  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.  

5)  INSTALL THE FRONT TAIL PIPE TO THE MUFFLER USING A 5” CLAMP.  USE THE MIDDLE 5” HANGER CLAMP AFTER THIS 5” CLAMP.  INSTALL THE WIRE HANGERS THAT ARE ON THE HANGER CLAMP TO THE O.E. RUBBER MOUNTS ABOVE.

6)  INSTALL THE REAR TAIL PIPE TO THE FRONT TAIL PIPE USING THE REAR 5” HANGER CLAMP TO THE TAIL PIPE.  CONNECT THE WIRE PORTION OF THE HANGER CLAMP TO THE O.E. RUBBER HANGER MOUNT ABOVE.

7)  FOR THOSE WITHOUT DUALLY MODELS, YOU WILL NEED TO TRIM THE TAIL PIPE TO LENGTH AND STYLE OF CUT.

8)  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 #4055525,:
1)  MUFFLER                     2)  5” CLAMPS # MC7500
1)  FRONT EXTENSION PIPE # 4055526        1)  FRONT 5” HANGER CLAMP # 2831
1)  23” MIDDLE EXTENSION PIPE # 4055523    1)  REAR 5” HANGER CLAMP #2829
1)  FRONT TAIL PIPE # 4055506            1)  MIDDLE 5” HANGER CLAMP # 2830    
1)  REAR TAIL PIPE # 4055507            1)  4” CLAMP # MC7400
            












INSTRUCTIONS FOR KIT #4055525    5” DIESEL KIT CAT-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