Edelbrock 5785 User Manual

EDELBROCK DIESEL EXHAUST SYSTEM

for 2002-2005 Dodge 5.9L

Quad Cab, Long & Short Bed

Catalog #5785

INSTALLATION INSTRUCTIONS

Please study these instructions carefully before installing your new Edelbrock Exhaust System. If you have any questions or
problems, contact our Technical Hotline at: 1-800-416-8628, 7am - 5pm, Monday-Friday, Pacific Standard Time or e-mail us at

[e-mail]. Please fill out and mail your warranty card.

Suggested Tools for Installation:

❑ 3/8" and 1/4” ratchet set and metric sockets ❑ 9/16” Combo wrench
❑ Hacksaw, sawzall, chopsaw ❑ Jack and jackstands
❑ Liquid penetrant and rubber lubricant

INSTALLATION INSTRUCTIONS

DISASSEMBLY

1. Lift and support vehicle on correct load rated jackstand
on stable surface.

2. Unbolt I-pipe.

3. Cutting overaxle pipe at rear of muffler will make
removing muffler, overaxle, and I-pipe assembly easier,
remove muffler, I-pipe, and overaxle at this time.

ASSEMBLY

1. Install I-pipe; Use I-pipe #25-3208 and hanger #25-4054
for short bed. Use I-pipe #25-3206 and hanger #25­4055 for long bed.

2. Install rear muffler hanger #23-4057 into factory
insulator.

3. Slide hanger #23-4056 over front of muffler. The inlet
end of the muffler is the end with the number stamped on
the end cap #25-5571. Slip muffler onto I-pipe and insert
hanger into insulator.

4. Install nut plate #23-4060 into large hole at the back of
the right side frame rail (the plate goes inside boxed
frame rail), then install tailpipe hanger #23-4059 using
supplied 7/16” bolt and washers. Bolt will go through the
large hole in the frame rail.

5. Install overaxle pipe and slip into muffler.

6. Install supplied isolator onto hanger #23-4059 and install
overaxle band clamp #23-4046 to hang overaxle pipe.

7. Dual rear wheel applications require supplied tailpipe
extension (#25-3205). Install tailpipe (#25-3204) onto
overaxle and through tailpipe hanger clamp assembly.

8. Starting at the front of the vehicle to rear, align and
tighten all clamps and hanger clamp assemblies. Position
system for clearance around surrounding hoses, lines,
cables, and frame members for best clearance.

9. Make one final inspection for clearance around brake,
fuel lines, and wiring. Drive vehicle and re-tighten
system.

WARNING!!!

Exhaust gas contains carbon monoxide,

a deadly invisible gas.

Correct any leaks before driving!

KIT CONTENTS

Qty. Part # Description

❑ 1 25-3204 Tail pipe assembly
❑ 1 25-3206 I-pipe assembly (Long Bed)
❑ 1 25-3208 I-pipe assembly (Short Bed)
❑ 1 25-3205 Tail pipe extension
❑ 1 25-5571 Muffler assembly
❑ 1 25-3207 Overaxle pipe assembly
❑ 1 22-5785 Installation kit hardware

Edelbrock Corporation

2700 California St., Torrance, CA 90503

Tech Line: [phone]

Office: [phone]

E-Mail: [e-mail]

©2005 Edelbrock Corporation
Catalog #5785

Brochure #63-0406

Rev. 6/05 - DA/mc