Edelbrock 6668 User Manual

TUBULAR EXHAUST SYSTEMS #6668

INSTALLATION INSTRUCTIONS

Applications: 2000 Dodge Dakota and Durango,

5.2L & 5.9L V8, Auto Transmission, 2 & 4 WD

§ PLEASE study these instructions carefully before installing your new Tubular Exhaust Systems (T.E.S.). If
you have any questions or problems, please call our Technical Hotline at: 1-800-416-8628 from
7:00 am - 5:00 pm, Monday-Friday, Pacific Standard Time or e-mail us at [e-mail].

§ TUBULAR EXHAUST SYST EM: These components are designed as a system to improve the exhaust
efficiency of the 5.2L & 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 protection
during shipping and storage. The parts can be identified by the part number 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
requires welding for installation and retains all O.E.M. emissions equipment.

§ SUGGESTED TOOLS FOR INSTALLATION: This vehicle has some metric fasteners.

ü 3/8” ratchet socket set with extensions and universal 13mm and 15mm swivel sockets
ü 12-point combination wrench set
ü Hack saw
ü Jackstands, screwdrivers, pliers, crescent wrench, etc.
ü 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: The paint used on T.E.S. is for protection during shipping and storage and will burn off soon after
the engine is started. Those who desire a longer lasting finish should sand blast the T.E.S. to remove the
original paint, then apply high temperature header paint, such as VHT, available at most auto parts stores.

- High temperature spark plug wires and boots are recommended to withstand heat from T.E.S.

§ DISASSEMBLY

1. Remove negative battery cable.

2. Raise vehicle and remove 02 sensor from factory Y -pipe; careful not to damage sensor.

3. Unbolt and remove factory Y -pipe and converter assembly.

4. Remove air inlet tube and air cleaner assembly.

5. Remove stock exhaust manifolds and gaskets.

6. Remove the center studs from cylinder head. (You will be us ing 5/16-18 x 1 header bolt 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: The hardened flat washers in kit are to be used on the slotted flange bolt
holes.

2. Reinstall air inlet tube and air cleaner assembly.

3. Cut the OEM Y -pipe 2 3/8” forward of front weld of catalytic converter assembly. (See Figure # 1).

4. Place catalytic converter in vehicle on hanger bracket and exhaust pipe.

5. Install new Y -pipe and crossover using supplied donut gaskets and hardware.

6. Align the Y-pipe assembly with the catalytic converter inlet. Check clearance to surrounding

components. On 4-wheel drive vehicles, be sure you have adequate clearance between crossover
pipe and front drive-shaft flange and U-joint. Tack weld new Y-pipe to inlet of catalytic converter.
Carefully remove the Y-pipe and catalytic converter assembly and finish welding the Y-pipe to the
catalytic converter.
NOTE: 4-wheel drive vehicles, it will be easier to install Y-pipe assembly with the front drive-shaft

unbolted from front differential yoke.

7. Using the supplied tie wraps, you can secure the shifter cable to the transmission cooler lines as

needed; be careful not to kink ca ble or lines.

8. Re-install O2 sensor into new Y -pipe (use anti-seize on threads).

§ FINAL INSPECTION

1. Check all hydraulic, vacuum and fuel lines to ensure there is adequate clearance to T.E.S.

components.

2. Reconnect battery.

3. At this point, it is a good idea to look over the complete installation to be sure nothing was missed.

4. Start vehicle and bring up to normal operating temperature and check for possible leaks, correct as

necessary.

5. Turn engine off and let cool then re-tighten all bolts again. (Do not do while HOT!).

§ KIT CONTENTS:

1 – Manifold left side #25-9080 8 – Flat washers; 5/16”
1 – Manifold right side #25-9150 4 – Hex capscrews; 3/8” – 16 x 2”
1 – Y -pipe #25-9615 2 – V8 port gaskets
1 – Crossover pipe #25-9664 2 – Donut gaskets
12 – header bolts; 5/16” – 18 x 1” 1 – U -clamp; 2-/4”
12 – Lock washers; 5/16” 2 – 11” Tie wraps
4 – Lock washers; 3/8”

PLEASE complete and mail your warranty card. Be sure to write the model number of this product in the “Part
#______” space. Thank you.

Edelbrock Corporation

2700 California Street

Torrance, California 90503

2000 Edelbrock Corporation Revised 10/00

C:\WINWORD\Installation Instruction\6668-TES For 2000 Dodge Dakota & Durango.Doc