INSTRUCTIONS FOR KIT #4405500
4” 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 MODELS WITH
CONVERTER, BUT REQUIRES MODIFICATIONS TO RE-INSTALL THE ORIGINAL
CONVERTER. IF ORIGINALLY EQUIPPED WITH A
CATALYTIC CONVERTER, IT IS ILLEGAL TO USE THE VEHICLE ON PUBLIC ROADS
WITH THE
CONVERTER REMOVED. NOTE:
FOR 1994-1998 MODELS THE TAIL PIPE HANGERS
MAY NEED TO BE MODIFIED OR REMOVED, AND AN ALTERNATE HANGER SETUP
INSTALLED.
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, YOU WILL NOT NEED THE 26” (SHORTER) EXTENSION
PIPE.
4) USE THE 4" CLAMP TO ATTACH THE 26” EXTENSION
PIPE TO THE DOWN PIPE (FOR EXTENDED CAB MODELS ONLY, REGULAR CAB TRUCKS
SKIP
THIS STEP).
5) ATTACH THE 39” EXTENSION PIPE (CUT TO LENGTH
IF NECESSARY) TO THE SHORTER 4” EXTENSION PIPE USING A 4” CLAMP.
6) INSTALL THE MUFFLER TO THE EXTENSION PIPE
USING THE FRONT 4” HANGER CLAMP.
NOTE: THE EXHAUST SHOULD FLOW
OVER, AND NOT DIRECTLY INTO, THE LOUVERS OF THE MUFFLER. 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.
7) INSTALL THE TAIL PIPE TO THE MUFFLER USING
THE REAR 4” HANGER CLAMP. INSTALL THE
WIRE HANGERS THAT ARE ON THE HANGER CLAMP TO THE O.E. RUBBER MOUNTS
ABOVE. INSTALL THE WIRE PORTION OF THE
HANGERS ON
THE TAIL PIPE TO THE O.E. RUBBER MOUNTS ABOVE THE HANGERS.
8) FOR THOSE WITH DUALLY MODELS, YOU WILL NEED
TO INSTALL THE TAIL PIPE EXTENSION TO THE TAIL PIPE USING BY EITHER
WELDING
(RECOMMENDED FOR APPEARANCE REASONS) OR USING A 4” CLAMP (INCLUDED). YOU MAY NEED TO TRIM TO LENGTH AND STYLE OF
CUT.
9) TIGHTEN ALL CLAMPS AND BOLTS AND CHECK FOR
CLEARANCE OF THE FRAME, BODY, AND BRAKE AND FUEL LINES.
HARDWARE
KIT FOR KIT
#4405500:
1) DOWN PIPE # 4405502
3)
4” STAINLESS STEEL CLAMPS # MC7400SS
1) 26” FRONT EXTENSION PIPE # 4405503 1)
FRONT 4” HANGER CLAMP # 2979SS
1) 39” REAR EXTENSION PIPE # 4405504
1)
REAR 4” HANGER CLAMP # 2978SS
1) TAIL PIPE # 4405506
1) TAIL PIPE EXTENSION # 4405507
1) MUFFLER #5024-114SS
INSTRUCTIONS FOR KIT #4405500
4” DIESEL KIT TURBO-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.
NOTE: THIS KIT
IS MADE OF 409 STAINLESS STEEL. IT MAY
BE BROWNISH IN COLOR, AND A MAGNET WILL STICK TO IT.
FOR
DETAILED DIGITAL
PICTURES OF THIS SYSTEM INSTALLED EMAIL US AT:
HEARTTHROB@WILLMAR.COM