Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Exhaust- Monster Sport Exhaust System '04-07 325 HP Dodge 5.9L HO Cummins Trucks, Including Mega Cab - Manual (Page 5)

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 may
require 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.
Starting at the rear of the vehicle,
remove the tailpipe near the muffler
clamps by cutting through the
connection or by removing the clamps
and heating the joints with an oxy-
acetylene torch to allow crimped pipes
to separate. Remove the tailpipe from
the vehicle.
4.
Remove the clamps on the catalytic
converter to the front muffler or if
applicable, the intermediate pipe
connection. TAKE CAuTION TO
NOT CuT OR DAMAGE CATALYTIC
CONVERTER TuBING DuRING THE
REMOVAL PROCESS. Separate the
muffler/ intermediate pipe to catalytic
converter connection.
Note: the use of an oxy-acetylene
torch may be necessary. Remove the
muffler hanger pins from the rubber
hangers with a pry bar (Spray lubricant
will ease hanger removal) and remove
the muffler/intermediate pipe or
muffler assembly from the vehicle.
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 grid work 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 grid
work. If your catalytic converter is
damaged, it may be covered under
your vehicle’s emissions warranty.
5.
For Crew Cab Long Bed & Mega
Cab models (160.5” wheelbase)
ONLY, install a 4” exhaust clamp onto
the front of the Banks intermediate
pipe. Install the intermediate pipe onto
the catalytic converter outlet. Install
the intermediate pipe hanger onto the
corresponding rubber hanger. Loosely
snug the 4” clamp.
6.
For all other models, Install a
4” exhaust clamp onto the front of
the Banks Extension pipe. Install the
extension pipe onto the catalytic
converter outlet. Loosely snug the 4”
clamp.
Monster Sport Exhaust System
Installation
96570 v.3.0
5