Edelbrock 66642, 66643 User Manual
TUBULAR EXHAUST SYSTEM
For 1997-1998 Dodge Dakota, 2&4 WD, 5.2L / 5.9L V8, Auto Transmission
1997-1998 Dodge Durango, 4WD, 5.2L / 5.9L V8, Auto Transmission
Catalog #66642, #66643
INSTALLATION INSTRUCTION
Please study these instructions carefully before installing your new Tubular Exhaust System (TES). If you have any
questions, please contact our Technical Hotline at : 1-800-416-8628 from 7 am - 5pm, Monday-Friday, Pacific
Standard Time or e-mail us at Edelbrock@Edelbrock.com. Please fill out and mail your warranty card.
TUBULAR EXHAUST SYSTEM: These components are designed as a system to improve the exhaust efficiency of the
Chrysler 5.2L and 5.9L V8 engine. They are constructed of 409 HP stainless steel to better withstand the high heat present
with the fuel-injected engine, especially when used for towing or other heavy duty applications. The stainless steel used
for these systems is much more durable than mild steel, although it does not appear different in appearance. These
systems come with a coat of black paint for good looks and protection during shipping and storage, and they can be
identified by the part numbers on each of the major components. Note that a magnet will stick to this type of stainless
steel; magnetic attraction is not a valid test for these systems. A performance gain can be expected by the installation of
the system. This system does not require welding for installation and retains all O.E.M. emissions equipment.
• Suggested Tools Needed for Installation: This vehicle has some metric fasteners.
— 3/8” ratchet socket set with extensions and universal 13mm and 15mm swivel sockets
— Combination set of open-end wrenches
— Hack saw
— Jackstands, screwdrivers, pliers, crescent wrench, etc.
— Liquid penetrant, (GM #1052627) anti-seize compound (GM #5613695)
• SPECIAL NOTICE: This Edelbrock part has received an Executive Order number (E.O. #) from the California Air
Resources Board (C.A.R.B.) making it legal for street use on pollution-controlled motor vehicles in all 50 states. To
assist you with emissions equipment certification, we have included a silver fan shroud decal to verify that this part is
a legal replacement part on the vehicle for which it is cataloged. The adhesive-backed decal should be affixed to your
fan shroud next to the existing emission and engine specification decal. Do not cover your original equipment
specification decal with the Edelbrock fan shroud decal.
• WARNING: The use of “Thermal Wrap” or any aftermarket coating process will void the warranty on your Tubular
Exhaust System. Those products can cause excessive heat and moisture buildup resulting in corrosion and early
failure of the system.
• NOTES: High temperature spark plug wires and boots are recommended to withstand head from T.E.S.
©2005 Edelbrock Corporation
Rev. 7/05 - DA/mc
Page 1 of 2
Catalog #66642 & #66643
Brochure #63-0429
INSTALLATION INSTRUCTIONS
DISASSEMBLY
1. Disconnect negative battery cable.
2. Raise vehicle and remove O2 sensor from factoryY-
pipe, careful not to damage.
3. Unbolt and remove Y-pipe assembly.
NOTE: Removing the Y-pipe from the catalytic
converter may require heating with a torch.
4. Remove air inlet tube and air cleaner assembly.
5. Remove exhaust manifolds.
6. Remove center studs from cylinder head. You will be
using the 5/16” - 18 x 1, header bolts in place of the
studs.
ASSEMBLY
1. Install T.E.S. flange gaskets and manifolds from top
along with header bolts, lock washers and flat
washers supplied. NOTE: Hardened flat washers
are to be used on slotted flange holes.
2. Re-install air inlet tube and air cleaner assembly.
3. Install crossover pipe into Y-pipe assembly. Then, using
the donut gaskets and hardware supplied in kit, install
the crossover and Y-pipe assembly onto header
collectors and catalytic inet.
4. Install clamps provided onto crossover pipe and
catalytic converter and tighten.
FINAL INSPECTION
1. Check all hydraulic, vacuum and fuel lines to ensure
there is adequate clearance to T.E.S. components.
2. Re-connect battery.
3. At this point, it is a good idea to look everything over
and make sure that nothing was missed in assembly.
4. Start vehicle and bring up to normal operating
temperature. Check for possible leaks.
5. Turn engine off and let cool. Tighten all bolts again.
Catalog #66642
Qty. Description
1 Manifold left side (#25-9309)
1 Manifold right side (#25-9322)
1 Y-Pipe (#25-9636)
1 Crossover pipe - left (#25-9635)
12 Header bolts; 5/16” - 18 x 1”
12 Lock washers; 5/16”
4 Lock washers; 3/8”
8 Flat washers; 5/16”
4 Hex capscrews; 3/8”-16 x 2”
2 V8 Port gaskets
2 Donut gaskets
1 U-clamp; 2-1/4”
1 Flange, collector
KIT CONTENTS
Catalog #66643
Qty. Description
1 Manifold left side (#25-9080)
1 Manifold right side (#25-9114)
1 Y-Pipe (#25-9636)
1 Crossover pipe - left (#25-9635)
12 Header bolts; 5/16” - 18 x 1”
12 Lock washers; 5/16”
4 Lock washers; 3/8”
8 Flat washers; 5/16”
4 Hex capscrews; 3/8”-16 x 2”
2 V8 Port gaskets
2 Donut gaskets
1 U-clamp; 2-1/4”
1 Flange, collector
Edelbrock Corporation
2700 California St.
Torrance, CA 90503
Tech Line: 1-800-416-8628
E-Mail: edelbrock@edelbrock.com
©2005 Edelbrock Corporation
Rev. 7/05 - DA/mc
Page 2 of 2
Catalog #66642 & #66643
Brochure #63-0429
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