Bully Dog Rapid Flow User Manual

INSTALLATION MANUAL

Dodge 5.9L Cummins 2500-3500 ‘04.5-’07 Part #

Rapid Flow 4” Turbo Back Dual Aluminized 82224

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 (866-285-

5936).

TABLE OF CONTENTS

INTRODUCTIONS .................................................................. PG 2

BILL OF MATERIALS .............................................................. PG 3

EXHAUST REMOVAL .............................................................. PG 4

EXHAUST INSTALLATION ...................................................PGS 5-8

QUICK LOCATION OVERVIEW.................................................................PG 5

INSTALLATION STEPS......................................................................PGS 6-8

TROUBLESHOOTING .............................................................. PG 9

This Application was designed as a performance cosmetic upgrade. Towing a 5th
wheel or bumper tow trailer with more than 500lbs tongue weight may result in
damage to your vehicle and/or the exhaust system.

3

Rapid Flow Exhaust # 82224

RAPID FLOW INSTALLATION

300 HP

400 HP

500 HP

600 HP

4” Exhaust

Systems for

HP Applications

Less Than

450hp

5” Exhaust

Systems for
HP Applications
Between 450hp

and 550hp

6” Exhaust Systems
for HP Applications

over 550hp

4”
Ceramic-Coated
Exhaust System

for all HP

Applications

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 ow which reduces exhaust tem­peratures, improves engine eciency and increases horsepower. This results in adding additional horse­power and fuel economy. This instruction set covers the 4” Rapid Flow Aluminized Dual Exhaust designed
specically for the 5.9L Cummins.

Note: This instruction set and the Rapid Flow Exhaust system included is made exclusively for the 5.9L

Cummins ‘04.5-’07.

BULLy DOg’S RULE OF ThUmB FOR ExhAUST SIzES

Rapid Flow Exhaust # 82224

4

RAPID FLOW INSTALLATION

BILL OF MATERIALS

1. 48” Straight Pipe

2. 24” Straight Pipe

3. Muffler

4. Y-Pipe

5. Passenger Front Piece Tail Pipe

6. Passenger Tail Pipe Tip

7. Driver Front Piece Tail Pipe

8. Driver Tail Pipe Tip

9. Hanger Bracket (2 pieces)

10. Clamps (6 Pieces)

11. Hangers (4 Pieces)

A. FRONT OF MUFFLER

B. REAR OF MUFFLER

C. PASSENGER TAIL PIPE TIP

D. DRIVER TAIL PIPE TIP

A.

B.

A.

C.

D.

B.

11.

10.

TOOLS NEEDED

- 9/16” Wrench

- Sawzall

- Silicone Spray Lubricant

-Channel Locks

C.

9.

9.

2.

3.

7.

1.

8.

5

Rapid Flow Exhaust # 82224

5.

4.

6.