Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Exhaust- Monster Exhaust, Split-Dual, out the sides '03-04 - Manual (Page 5)

96482 v.4.0
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1.
As a precaution, disconnect the
ground of the battery (if there is more
than one battery, disconnect both).
2.
Raise the vehicle and support it with
properly weight rated safety stands,
ramps or a commercial hoist. Follow
the manufacturer’s safety precautions.
Take care to balance the vehicle to
prevent it from slipping or falling. When
using ramps, be sure the front wheels
are centered squarely on the topsides;
place the transmission in park; set
the parking brake and place blocks
behind the rear wheels. CAUTION: DO
NOT WORK UNDER ANY VEHICLE
SUPPORTED ONLY BY A JACK.
SEVERE INJURY MAY RESULT.
WARNING! The following step
requires the use of a torch and/or
saw. Proper safety equipment
should be used. Failure to use
proper safety equipment may
result in severe injury.
3.
From under the vehicle, remove the
entire factory exhaust system. Starting
at the rear of the vehicle, remove
each component by either cutting
through the pipe near the clamps or
by removing the clamps and heating
the joints with an oxy-acetylene torch
to allow crimped pipes to separate.
DO NOT CUT OR DAMAGE CATALYTIC
CONVERTER TUBING DURING THE
REMOVAL PROCESS. Remove the
hanger pins from the rubber hangers
with a pry bar. (Spray lubricant will
ease hanger removal.)
4.
Remove the clamp attaching
the turbine outlet pipe (T.O.P) to
the catalytic converter headpipe
(or intermediate pipe if applicable)
and remove the catalytic converter
assembly or intermediate pipe.
Remove the band-clamp that attaches
the T.O.P. to the turbine outlet elbow
and remove the factory T.O.P from the
vehicle.
5.
Remove the V-band clamp that
attaches the turbine outlet elbow to
the turbine housing and remove the
turbine outlet elbow from the vehicle.
6.
Attach the supplied T.O.P. gasket
to the Banks T.O.P. Loosely place the
supplied V-band clamp on the Banks
T.O.P. Install the Banks T.O.P. to the
turbine housing (note: the factory
turbine outlet elbow will not be
used). Loosely snug the V-band clamp
assuring gasket and T.O.P are aligned
properly.
7.
For vehicles that are NOT equipped
with a catalytic converter, install the
supplied Banks front intermediate
pipe and supplied gasket onto the
previously installed Banks T.O.P. Place
a small amount of anti-seize onto the
four (4) 7 ⁄
16
” bolts. Loosely install the
supplied 7 ⁄
16
” hardware onto the T.O.P.
and intermediate pipe flange (see
Figure 1). Proceed to Step 9.
8.
For vehicles equipped with catalytic
converters:
IMPORTANT: If the vehicle
is equipped with a catalytic
converter, it should be inspected.
Diesel catalysts may become
plugged with soot and can cause
a restriction to exhaust flow,
impeding performance. Shine a
powerful flashlight into the inlet
end of the converter. Observe the
light through the other end of the
converter. The full circle of the
flashlight should be visible without
any blockage in the gridwork of
the catalyst. If excessive soot is
observed, the catalyst may need
to be cleaned. TAKE PRECAUTIONS
to avoid blowing soot toward the
work area or where it could be
inhaled. ALWAYS use breathing
protection. Also inspect the
catalyst for damage (i.e. chips,
bent corners, etc.) to the gridwork.
Monster Exhaust System Installation