INSTALLATION Manual Dodge 5.9L Cummins 2500-3500 ‘04.
RAPID FLOW INSTALLATION TROUBLESHOOTING: Please review the Troubleshooting section on page 9 before calling technical support to cover most common issues.Technical support is available by calling 866-bullydog (866-2855936). TABLE OF CONTENTS INTRODUCTIONS................................................................... PG 2 BILL OF MATERIALS............................................................... PG 3 EXHAUST REMOVAL . .............................................................
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, improves engine efficiency and adds horsepower. This instruction set covers installation of the 6” Rapid Flow Aluminized Catback Exhaust designed specifically for the 5.9L Cummins.
RAPID FLOW INSTALLATION Bill of Materials 1. Adaptor 2. 60” Straight Pipe (182062 only) 3. 40” Straight Pipe (N/A on this kit) 4. 24” Staight Pipe (N/A on this kit) 5. Muffler 6.Front Piece Tail Pipe 7. Tail Pipe Tip 8. Clamps (3 Pieces) 9. Hangers (3 Pieces) A. Front Of muffler B. Rear of muffler C. tail pipe Tape Tools Needed - 9/16” Wrench - Sawzall - Silicone Spray Lubricant -Channel Locks A. 9. C. B. 5. 8. 3. 4. 2. 1. 6. 7.
RAPID FLOW INSTALLATION Removal of Stock Exhaust System In these steps you will remove the stock exhaust system. Important: It is illegal in all 50 states and Canada to remove the catalytic converter. 1.Use a sawzall to cut the exhaust directly behind the muffler. 2. Cut the Straight Pipe in front of the muffler. 3. Cut the stock Down Pipe just after the bend. Cut directly in front of the Muffler 4.
RAPID FLOW INSTALLATION Quick Overview FULL Exhaust Straight Pipe Front Piece Tail Pipe Tail Pipe Tip Catalytic Converter (Stock) Adapter Muffler Clamp and hanger Placement Hanger B Clamp Hanger C 5 Hanger A Clamp
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 A Hanger B Hanger C 1.
RAPID FLOW INSTALLATION Note: At this point you will skip installing the Straight Pipe(s) and start at the Muffler and work back toward the rear of the vehicle. 4. Hang the Muffler from Hangers A & B. Hanger A Install Muffler 5. Install the Front Piece Tail Pipe by sliding it into the Muffler and tightening Hanger B to hold it in place. Ensure that the bend of the is directly over the axle.
RAPID FLOW INSTALLATION 7. At this point it is time to install the Straight Pipe. Measure and cut the Straight Pipe for the final fit, leave 3” on both sides for overlap. Measure for Straight Pipe Catalytic Converter Adapter Straight Pipe 8. 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. 9. Return to each of the Clamps and tighten with a 9/16” wrench.
RAPID FLOW INSTALLATION Troubleshooting/FAQ CONDITION Exhaust Rattle 9 POSSIBLE SOURCES Exhaust Sounds ACTION Either one of the Clamps is not tight or the exhaust is coming in contact with the chasis or body. Adjust the exhaust to ensure that no contact is made.
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Doc.# 182062-99 V2.0 Check out more of our Adrenaline Pumping products! Downloaders Intake Systems Triple Dog GT Exhaust Systems ® Free Technical Support at: 866-bullydog (866-285-5936) See More at: bullydog.
