INSTALLATION Manual GM 6.
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 INTRODUCTION.................................................................................................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 Dual Aluminized Exhaust, an exhaust designed to give that unique look and functionality.
RAPID FLOW INSTALLATION Exhaust Components Tools Needed 1. Down Pipe 2. Straight Pipe 3. Cross Member 4. Muffler Y-Pipe 5. Front pipe extension 6. Tail Pipe Tip (2 pieces) 7. Driver Front Piece Tail Pipe 8. Passenger Front Piece Tail Pipe 9. Hanger Bracket 10. Clamps (7 Pieces) 11. Hangers (6 Pieces) - 9/16” Wrench - Sawzall (Recommended) - Silicone Spray Lubricant -7/16” Deep Socket - Socket Wrench A. On Down Pipe B. Cross Member #1 C. Cross Member #2 D. Behind Muffler E. Driver Side Tail Pipe F.
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 immediately behind the muffler. Important: It is illegal in all 50 states and Canada to remove the catalytic converter. LB7 vehicles are not generally equipped with a catalytic converter. 2. Use a sawzall to cut the exhaust immediately behind the Catalytic Converter. Warning: The 6.6L Duramax is equipped with a two piece down pipe.
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 the downpipe using the factory turbo clamp. Snug the clamp down so that it will hold the pipe. 3. Place all of the supplied Hangers except Hanger E into their appropriate locations as shown in the diagram. Hangers B & C will hold the cross member. Hanger D will serve as a clamp on the Y Pipe Muffler. Hanger F will hold the Passenger Side Tail Pipe. Hanger E will hold the Driver Side Tail Pipe. 9/16” Install all Hangers 4.
RAPID FLOW INSTALLATION Switch Directions: The next steps will be from the back of the truck 9. Install the Y Pipe Muffler by hanging the Y pipe from Hanger D. You will need two clamps to secure both the Passenger Side Tail Pipe and the Driver Side Tail Pipe. The Y Pipe will need to be installed vertically. The Passenger Side Tail Pipe is fitted into the lower extension and the Driver Side Tail Pipe will be in the upper extension as shown. Hanger D 10.
RAPID FLOW INSTALLATION 14 At this point, if you need the extra Straight Pipe, cut the Straight Pipe to the desired length. Keep in mind that you need 3 inches of overlap when you cut the pipe. If you don’t need the straight pipe, simply install the muffler directly into the Cross Member section. If the straight pipe is not needed, you will have an extra straight pipe and an extra clamp left over when you are finished. 3” 15.
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 # 83222 12
Doc.# 83222-99 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.
