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 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 Cat Back Exhaust for the 6.6L GM Duramax vehicles ‘06-’07.
RAPID FLOW INSTALLATION Exhaust Components Tools Needed 1. 3.5”-4” Adapter 2. 4”-5” Adapter 3. Cross Member 4. Muffler 5. Front Piece Tail Pipe 6. Tail Pipe Tip 7. Clamps (5 Pieces) 8. Hangers (5 Pieces) - 9/16” Wrench - Sawzall (Recommended) - Silicone Spray Lubricant - Socket Wrench A. On Down Pipe B. Cross Member #1 C. Cross Member #2 D. Behind Muffler E. Front Piece Tail Pipe A. C. B. D. 4. 7. 8. 6. 3. 2. 5. 1.
RAPID FLOW INSTALLATION Removal of Stock Exhaust System Important: It is illegal in all 50 states and Canada to remove the catalytic converter. Catalytic Converters must be reinstalled in accordance with Federal Law. In these steps you will remove the stock exhaust system. 1. Use a sawzall to cut the exhaust immediately behind the muffler. Cut Exhaust after muffler 2. Use a sawzall to cut the exhaust in back of the Catalytic Converter and in front of the band clamp.
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 • • Socket Wrench Tape Measure 1. It is suggested that before installing the system on the truck, the Rapid Flow Exhaust System be laid out on a large flat surface to acknowledge the location of each piece Quick Overview FULL Exhaust Adapter 4”-5” Cross Member Adapter 3.
RAPID FLOW INSTALLATION 2. Place all of the supplied Hangers into their appropriate locations. Hang the Hangers 3. Install the Muffler using hanger C. This will determine where everything else will go. Install Muffler Hanger C Clamp Front Piece Tail Pipe Installing Front Piece Tail Pipe 4. Install the Front Piece Tail Pipe into the muffler and secure with clamp.
RAPID FLOW INSTALLATION 5. Next install the Tail Pipe Tip into the Front Piece Tail Pipe. Ensure that the desired location will not come in contact with the body of the truck or blacken the paint. Confirm that the bend of the Front Piece Tail Pipe Tip is directly over the rear axle. Hanger C Front Piece Tail Pipe Clamp Rear Piece Tail Pipe Front Piece Tail Pipe Hanger D 6. Tighten the Clamp by hand between the Tail Pipe Tip and the Tail Pipe. Tail Pipe Tip 7.
RAPID FLOW INSTALLATION Adapter Cross Member Hanger A 8. Install the Cross Member Pipe ensuring that the pipe follows the 3” bend of the truck’s cross member. You may need to cut the Cross Member Pipe to ensure that it fits over the cross member and line up with the muffler and the catalytic converter. Keep in mind that you need 3 inches of overlap when you cut the 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.
RAPID FLOW INSTALLATION Rapid Flow Exhaust # 83411 12
Doc.# 83411-99 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.
