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 TheBullyDogRapidFlowExhaustSystemshavebeenspeciallydesignedtoallowthelowestmandrelbendsin theindustry.Thelowermandrelbendsallowincreasedairflowwhichreducesexhausttemperatures,improves engine efficiency and increases horsepower.This results in adding additional horsepower and fuel economy. This instruction set covers the 5”Rapid Flow Aluminized Exhaust designed specifically for the 5.9L Cummins.
RAPID FLOW INSTALLATION Exhaust Components Tools Needed 1. Down Pipe 2. Adapter Pipe 3. Straight Pipe (2 Pieces) 4. Muffler 5. Front Piece Tail Pipe 6. Tail Pipe Tip 7. Clamps (6 pieces) 8. Hangers (4 pieces) A. On Down Pipe B. Front of Muffler C. Rear of Muffler D. Front Piece Tail Pipe - 9/16” Wrench - Sawzall - Silicone Spray Lubricant -Channel Locks -7/16” Deep Socket -Socket Wrench B. D. C. A. 4. 8. 5. 7. 1. 2. 6. 3. 5 3.
RAPID FLOW INSTALLATION Removal of Stock Exhaust System In these steps you will remove the stock exhaust system. 1. Use a sawzall to cut the exhaust directly behind the muffler. 2. Cut the Straight Pipe 4” behind the Catalytic Converter. Cut directly in front of the Muffler 7/16” 3. Cut the stock Down Pipe just after the bend. 4. Loosen the stock band clamp using a 7/16” deep socket where the stock down pipe is connected to the turbo.
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. Hang each of the hangers. Hanger A is on the Down Pipe, Hanger B and C will serve a dual purpose, serving as both hangers and clamps. Hanger B will be at the front of the Muffler and Hanger C will be at the rear of the Muffler. Hanger D will hold the Tail Pipe Tip. Hang the Hangers Hanger B Hanger C Install Down Pipe 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. Hanger B Install Muffler 6. 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 Front Piece Tail Pipe 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 8. 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 Pipe. Don’t cut the flared end. 3” Measure for Straight Pipe 9.
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.
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Doc.# 82410-99 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.
