Pypes Performance Exhaust STD052 - Manual

STD052
1994-2002 Dodge 5.9L 5” Turbo-back - 409SS
Tools needed: 9/16” end wrench or socket, 7/16” deep socket, hacksaw
or sawzall, aerosol lubricant.
(If your vehicle is equipped with a catalytic converter, it is unlawful
to remove.)
Removal of Original System
1) Start under the vehicle. Remove the two bolts that hold the stock down pipe to the cast iron elbow on the turbo. Save these
bolts for re-use.
2) Cut the original system in two places, first next to the transmission and second, just behind the muffler.
3) Spray the stock hangers with aerosol lube and pry rubber mounts from the system. Leave the rubber mounts attached to the
truck for re-use.
4) Remove the old system.
Installation of New Performance System
(Hint: Do not fully tighten any clamps until the complete system is installed and aligned.)
1) From under the truck, install the down pipe with the stock bolts.
2) Install one straight pipe into the muffler inlet and the first tailpipe section into the muffler outlet using the bare clamps.
3) Depending on muffler length you may need to trim the first section tail pipe to fit over axle. 30” mufflers will need to trim
approximately 3” off the end that goes in the muffler.
4) Temporarily hang the muffler in the stock location using the hanger clamp on the straight pipe and the hanger clamp on the
first tailpipe section.
5) Rotate the tailpipe as needed to pass next to the shock absorber and over the rear axle.
6) Install the second tailpipe into the outlet of the first tailpipe with a clamp. Rotate as needed to level the outlet behind the
right rear tire. Attach the hanger clamp to the second tailpipe using the rubber in the stock location.
7) Measure between the outlet of the down pipe and the inlet of the straight pipe. (Add 5” to this measurement for the slipjoints.)
8) Cut the next straight pipe to length and install between the down pipe and the straight pipe already installed using a clamp at
the down pipe and one on the straight pipe inlet.
9) Starting at the turbo, align all pipes and tighten all clamps. Start the engine and check for leaks.
Pypes Performance Exhaust
2880 Bergey Road Unit O Hatfield, PA 19440
800-421-3890 (voice) 215-712-9968 (fax)
www.pypesexhaust.com
4”
Downpipe