INSTALLATION Manual Dodge 5.
RAPID FLOW INSTALLATION TROUBLESHOOTING: Technical support is available by calling 866-bullydog (866-285-5936). TABLE OF CONTENTS INTRODUCTIONS................................................................... PG 2 BILL OF MATERIALS............................................................... PG 3 EXHAUST REMOVAL . ............................................................. PG 4 EXHAUST INSTALLATION....................................................PGS 5-8 QUICK LOCATION OVERVIEW....................
RAPID FLOW INSTALLATION INTRODUCTION The Bully Dog Rapid Flow Exhaust Systems have been specially designed to allow the lowest mandrel bends in the industry. The lower mandrel bends allow increased air flow which reduces exhaust temperatures, and helps to improve engine efficiency and max horsepower. This instruction set covers the installation of the 6” Turbo Back Rapid Flow Exhaust for the ‘94-’02 Dodge 5.
RAPID FLOW INSTALLATION Bill of Materials Tools Needed 1. Downpipe 2. Adaptor with Offset 3. 40” Straight Pipe (N/A for this kit) 4. 24” Straight Pipe (N/A for this kit) 5. 60” Straight Pipe (182060 only) 6. Muffler 7. Front Front Tail Pipe 8. Tail Pipe 9. Clamps (3 pieces) 10. Hangers (4 pieces) - 13mm Socket Wrench - Sawzall (Recommended) - Silicone Spray Lubricant - Socket Wrench -24” Extension - Pliers A. Down Pipe B. Front of Muffler C. Rear of Muffler D. Tail Pipe Tip 10. A B D C 6. 9. 4. 7.
RAPID FLOW INSTALLATION Removal of Stock Exhaust System In these steps you will remove the stock exhaust system. 1. You will need a ratchet with a 24” extension in order to remove the stock13mm bolts that hold the down pipe onto the turbo. You may have to combine different extensions to make the 24” extension. It is recommended that you use a silicone spray lubricate to help make the process easier. You will reuse the stock bolts to attach the new Rapid Flow exhaust.
RAPID FLOW INSTALLATION Quick Overview FULL Exhaust 60” or 40” Straight Pipe 24” Straight Pipe Down Pipe Adaptor with Offset Muffler Front Piece Tail Pipe Tail Pipe Tip Clamp and hanger Placement Hanger B Hanger C Hanger A Clamp Clamp Clamp Hanger D 5
RAPID FLOW INSTALLATION Installation of the Bully Dog Rapid Flow Exhaust System Important: Do Not over-tighten clamps. Too much torque will result in deformation of the exhaust. For best results when doing the installation, tighten the clamps enough to hold the exhaust pieces in place, but don’t tighten down until the entire exhaust system is installed. Hanger B Hanger D Hanger C Hanger A 1.
RAPID FLOW INSTALLATION Note: At this point it is recommended that you install the Muffler and work back to the rear of the vehicle, leaving the second Straight Pipe out. The second Straight Pipe is the piece that will be cut if needed in this one-cut system. 5. Hang the Muffler from Hangers B and C. Ensure that the louvers in the muffler are facing towards the front of the vehicle. Muffler Hanger B Hanger C Install muffler 6. Install the Front Piece Tail Pipe over the rear axle.
RAPID FLOW INSTALLATION 8. At this point, it is time to install the Straight Pipe. Cut the Straight Pipe to the desired length, keeping in mind that you need 3 inches of overlap when you cut the pipe. Do not cut the flarred end. Measure for Straight Pipe 9. Once the entire exhaust system is installed, inspect the system to ensure that no part of the exhaust is in direct contact with the chassis or body; adjustments may be necessary.
RAPID FLOW INSTALLATION Troubleshooting/FAQ CONDITION Which is better a 4”, 5” or 6» exhaust system? Exhaust Rattle Exhaust is too loud POSSIBLE SOURCES ACTION General It really depends on the application. A bigger exhaust system will allow more airflow and lower exhaust temperatures. However too large of an exhaust system without other increases in horsepower will lower back pressure and give the vehicle a sluggish start.
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