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 increases horsepower. This instruction set covers the 4” Rapid Flow Aluminized Turbo Back Exhaust and the 4” Rapid Flow Ceramic Coated Turbo Back Exhaust designed specifically for the 5.9L Cummins, both systems install the same way.
RAPID FLOW INSTALLATION Exhaust Components Tools Needed 1. Down Pipe 2. 24” Straight Pipe 3. 48” Straight Pipe 4. Muffler 5.Front Piece Tail Pipe 6. Tail Pipe Tip 7. Clamps (5 Pieces) 8. Hangers (5 Pieces) A. On Down Pipe B. Front of Muffler C. Rear of Muffler D. Front Piece Tail Pipe E. Optional - 9/16” Wrench - Sawzall - Silicone Spray Lubricant -Channel Locks 8. A. E. D. B. 7. 6. c. 4. 5. 1. 2. 3.
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. 4.Cut behind the Catalytic Converter and in front of it . 5.
RAPID FLOW INSTALLATION Installation of the Bully Dog Rapid Flow Exhaust System In these steps you will install the Rapid Flow Exhaust System. Tool s Needed: • Silicone Spray Lubricant • 9/16” Wrench • • • 7/16” Deep Socket Socket Wrench Tape Measure 1.
RAPID FLOW INSTALLATION 2. Install all the hangers. Hanger B Hanger C 3. Install the down pipe, using the stock band clamp, do not tighten. Hang the Hangers Install Down Pipe Stock Band Clamp Down Pipe 4. Install Hanger A to secure the down pipe. Down Pipe 5.
RAPID FLOW INSTALLATION Switch Directions: The next steps will be from the back of the truck 6. Hang the Muffler from Hangers B & C. Hanger B Install Muffler Front Piece Tail Pipe 7. Install the Front Piece Tail Pipe by sliding it into the Muffler and tightening Hanger C to hold it in place. Ensure that the bend of the is directly over the axle. At this point don’t tighten down Hanger C completely, instead wait until the entire exhaust is installed before tightening everything down completely.
RAPID FLOW INSTALLATION 9. At this point it is time to install the Straight Pipe(s). You will need to measure and cut the Straight Pipe(s) for the final fit. Keep in mind when you make your final cut you will need to leave an extra 3 inches of overlap when you cut the Straight 3” Pipe. Do not cut the flared end. Straight Pipe Clamp Hanger A Muffler Measure Straight Pipe 10.
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 How to Maintain HPC HiPerCoat® Coatings Congratulations for choosing the finest coatings available. We’ve engineered our exhaust coatings to provide a durable, long lasting finish. HPC’s coatings are guaranteed, no-nonsense products, which are proven winners in every facet of motorsports. If properly maintained your HPC protected parts will provide you with years of satisfaction. The following are some helpful suggestions to maintain your HPC coated components.
Doc.# 82400-99 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.
