INSTRUCTIONS FOR KIT #4405520
4” DIESEL KIT TURBO-BACK KIT
FITS:
2003-2004 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. DOES NOT FIT 2004-1/2 WITH
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 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.
2) INSTALL THE DOWN PIPE TO THE TURBO USING THE
ORIGINAL V-BAND CLAMP. 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 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” (SHORTER) EXTENSION PIPE.
4) USE A 4" CLAMP TO ATTACH THE I.D. INLET
OF THE 45” EXTENSION PIPE TO THE DOWN PIPE.
5) FOR CREW CAB LONG BOX MODELS ONLY, ATTACH THE
I.D. INLET OF THE 23” EXTENSION PIPE TO THE 45” EXTENSION PIPE USING A
4” CLAMP.
6) INSTALL THE MUFFLER TO THE APPLICABLE
EXTENSION
PIPE USING THE FRONT 4” HANGER CLAMP.
NOTE: THE EXHAUST SHOULD FLOW
OVER, AND NOT DIRECTLY INTO, THE LOUVERS OF THE MUFFLER. 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.
7) INSTALL THE TAIL PIPE TO THE MUFFLER USING
THE MIDDLE 4” HANGER CLAMP. INSTALL THE
WIRE HANGER THAT IS ON THE HANGER CLAMP TO THE O.E. RUBBER MOUNT ABOVE
ON THE
SIDE THAT IS NEAREST TO THE DRIVESHAFT. THERE
IS ANOTHER O.E. HANGER ON THE OPPOSITE SIDE OF THE HANGER NEAREST TO
THE
DRIVESHAFT THAT IS NOT USED IN THIS KIT.
8) INSTALL THE REAR 4” HANGER CLAMP TO THE TAIL
PIPE BEFORE THE LAST BEND AND JUST BELOW THE O.E. RUBBER HANGER MOUNT
JUST
BEHIND THE REAR AXLE. CONNECT THE WIRE
PORTION OF THE HANGER CLAMP TO THE O.E.
RUBBER HANGER MOUNT ABOVE.
9) FOR THOSE WITH DUALLY MODELS, YOU WILL NEED
TO INSTALL THE I.D. INLET OF 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.
10) 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
#4405520:
1) DOWN PIPE # 4405521
3)
4” STAINLESS STEEL CLAMPS # MC7400SS
1) 45” FRONT EXTENSION PIPE # 4405522 1)
FRONT 4” HANGER CLAMP # 2874SS
1) 23” REAR EXTENSION PIPE # 4405523
1)
REAR 4” HANGER CLAMP #2872SS
1) TAIL PIPE # 4405506
1) MIDDLE 4” HANGER CLAMP # 2873SS
1) TAIL PIPE EXTENSION # 4405507
1) MUFFLER #5024-114SS
INSTRUCTIONS FOR KIT #4405520
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