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2003 Dodge 5.9L Cummins H.O. 5″ Exhaust Diesel Performance Systems Installation

December 23rd, 2009 · No Comments

Removal of original system
1.) start under the hood. locate the turbo. remove the v-clamp from the turbo outlet. loosen the bolt enough to unlatch the t-bolt, then pry the clamp away from the flange at three spots using a flathead screwdriver.
2.) from underneath your vehicle, cut the stock system in two places. first, cut the turbo down pipe next to the transmission just after the bend where the pipe becomes level. second, cut the stock exhaust directly behind the muffler. spray the stock rubber hangers with lubricant (wd-40 or equivalent). using a pry bar, remove the stock hangers from the rubber grommets. remove the stock exhaust system from the vehicle

Installation of diesel performace systems-4โ€ exhaust system
1.) from underneath the vehicle, install turbo down pipe (turbo 1). rotate the turbo pipe as needed to mate up to the turbo outlet. reinstall the v-clamp at the turbo (reuse the stock clamp for this step). snug the clamp down so it will hold but can still be moved. attach hanger #1 to the turbo pipe. do not tighten completely.
2.) take the rubber grommet from the frame mount that is located at the front of the original muffler. this grommet will be used for hangers #2a & #2b. most, but not all dodge trucks have a pre-existing hole in the frame for hanger #2a. if the hole is not present in the frame already you will need to drill a hole to mount to hanger #2a midway on extension 2 using the bolt supplied. using the rubber grommet from the factory system, install the hanger #2a and then install hanger #2b. install all the remaining hangers. the hangers are numbered and start with the lowest number at the front of the vehicle.
3.) position the back of the muffler in hanger #3 (note: you will need to support the front of the muffler for step #4).
4.) install the extension (extension 2) on the back of the turbo pipe. posiition a 5โ€ u-bolt clamp at the connection but do not tighten. place hanger #2 in position but do not tighten. extension may need to be cut depending upon wheel base.
5.) install the front of the muffler to the rear of the extension. position a 5โ€ u-bolt clamp at the connection between the extension and the muffler. do not tighten clamps.

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