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, improved engine efficiency and increased horspower. This instruction set covers the 4” Rapid Flow Aluminized Dual Exhaust designed specifically for the 5.9L Cummins. Note: This instruction set and the Rapid Flow Exhaust system included is made exclusively for the 5.
RAPID FLOW INSTALLATION Bill of Materials Tools Needed 1. Down Pipe 2. 48” Straight Pipe 3. 24” Straight Pipe 4. Muffler 5. Y-Pipe 6. Passenger Front Piece Tail Pipe 7. Passenger Tail Pipe Tip 8. Driver Front Piece Tail Pipe 9. Driver Tail Pipe Tip 10. Hanger Bracket (2 pieces) 11. Clamps (6 Pieces) 12. Hangers (4 Pieces) A. On Down Pipe B. Front of Muffler C. Rear of muffler D. Passenger Tail pipe tip E.
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 7/16” 4.
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. Hang each of the hangers. Hanger A is going onto the Down Pipe Hangers B and C will serve a dual purpose acting as both clamps and hangers on the muffler. In order to hang the Hangers D and E, you will need to install the Hanger Brackets. No drilling is required as there are already holes in the frame at the correct locations. Hanger B Hang the Hangers Hanger Bracket 3. Install the Down Pipe by hanging it from the hanger and securing it to the turbo with the stock band clamp.
RAPID FLOW INSTALLATION Switch Directions: The next steps will be from the back of the truck 5. Hang the Muffler from Hangers B & C. Ensure that the louvers are pointing towards the front of the vehicle. Hanger C Muffler 6. Install the “Y” piece into the back of the Muffler. Secure by tightening Hanger B. The Y Pipe will sit straight up and down. Install Muffler Muffler Y-Pipe Hanger C Install Y-Pipe 7.
RAPID FLOW INSTALLATION 3” Muffler Measure Straight Pipe 11. Snug up the Hangers to hold the system in place but do not tighten completely as the system may need to be adjusted in future steps. 12. At this point it is time to install the Straight Pipe. You will need to measure and cut the Straight Pipe 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 Pipe. Do not cut the flared end. 13.
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 # 82223 12
Doc.# 82223-99 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.
