INSTALLATION Manual Dodge 5.
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 increases horsepower. This instruction set covers the 5” Rapid Flow Aluminized Exhaust for the ‘94-’02 Dodge Cummins 5.9L.
RAPID FLOW INSTALLATION Exhaust Components Tools Needed 1. Downpipe 2. Adaptor 3. Straight Pipes 4. Muffler 5. Front Tail Pipe 6. Tail Pipe 7. Hanger Bracket 8. Clamps (3 pieces) 9. 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 8. B D 7. C A 4. 9. 5. 2. 6. 1. 3. 3.
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 13mm 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 Installation of the Bully Dog Rapid Flow Exhaust System In these steps you will install the Rapid Flow Exhaust System. Bully Dog’s Exhaust Systems are onecut systems, meaning that you should only have to cut one pipe or less if installed correctly. Tool s Needed: • Silicone Spray Lubricant • 9/16” Wrench • • • 7/16” Deep Socket Socket Wrench Tape Measure 1.
RAPID FLOW INSTALLATION 2. Place all of the supplied Hangers into their appropriate locations as shown in the above diagram. Most Hangers will serve a dual purpose, acting as both clamps and hangers. Hanger A will serve as the clamp between the Down Pipe and the Adapter with Offset. Hangers B and C will act as both clamps and hangers to hold the muffler. Hanger D will hold the Tail Pipe Tip. Hanger B Hanger C 3. Bolt the Down Pipe in place using the stock 13mm bolts.
RAPID FLOW INSTALLATION Switch Directions: The next steps will be from the back of the truck 6. Hang the Muffler from Hangers B and C. Muffler Hanger B Hanger C 7. Install the Front Piece Tail Pipe over the rear axle. Confirm that the bend of the Tail Pipe is directly over the rear axle. The Front Piece Tail Pipe will hang from both Hangers C and D. Install muffler Hanger C Muffler Hanger B Front Piece Tail Pipe 8. Install the Tail Pipe Tip. There are extra clamps included in this exhaust set.
RAPID FLOW INSTALLATION 9. 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 3” cut the pipe. Do not cut the flarred end. Measure for Straight Pipe 10. 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 Exhaust Rattle Exhaust is too loud POSSIBLE SOURCES Exhaust Sounds Exhaust Sounds ACTION Either one of the clamps is not tight or the exhaust is coming in contact with the chassis or body. Adjust the exhaust to ensure that no contact is made. If your exhaust seems too loud, Bully Dog can sell you another muffler which will allow you to double stack mufflers. This extra muffler would take place of one of the straight pipes included with this system.
RAPID FLOW INSTALLATION Rapid Flow Exhaust # 82020 12
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