Edelbrock 66792, 66793 User Manual

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Brochure #63-66792

Rev. 1/07 - DA/mc

TUBULAR EXHAUST SYSTEM

For 2004-2005 Dodge Ram Pick-Up, 1500 Series,

2WD/IFS, 4WD 5.7L Hemi V8, Automatic Transmission

Catalog #66792 & 66793

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

TUBULAR EXHAUST SYSTEM: These components are designed as a system to improve the exhaust efficiency of the Dodge 5.7L Hemi 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 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 require welding for installation (see note below) and retains all O.E.M. emissions equipment. Not designed for vehicles with solid front axle

Suggested Tools Needed for Installation: This vehicle has some metric fasteners.

❑ Mig welder (recommended) or gas welder - Professional welding is highly recommended. ❑ 3/8” rachet, sockets, standard and deep SAE and metric & 13mm stubby combo wrench with extensions and

universal 13mm and 15mm swivel sockets

❑ Combination set of open-end wrenches ❑ Hacksaw or Sawzall ❑ Jackstands, screwdrivers, pliers, crescent wrench, etc. ❑ Liquid penetrant, (GM #1052627) and anti-seize compound (GM #5613695)

SPECIAL NOTICE: This Edelbrock Tubular Exhaust System has received an Executive Order number (E.O.#) from the California Air Resources Board (C.A.R.B.) making it legal for street use in all 50 states. To assist you with emission equipment certification, we have included a silver fan shroud decal to help testing personnel verify that this part is a legal replacement on the vehicle for which it is cataloged. The adhesive-backed decal should be affixed next to the existing emission and engine specifications decal. Do not cover any part of your original emission decal.

WARNING: The use of "Thermal Wrap" or any aftermarket coating process will void the warranty

on your Edelbrock Tubular Exhaust Systems. Those products can cause excessive heat and moisture buildup resulting in corrosion and failure of the system.

IMPORTANT NOTE:

When cleaning any ceramic-coated Edelbrock T.E.S., use only soap and warm water. The use of caustic solvents (i.e. gunks, etc.) will mar or damage the ceramic-coating.

IMPORTANT NOTE:

Proper installation is the responsibility of the installer. Improper installation will void warranty and may

result in poor performance and engine or vehicle damage.

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Brochure #63-66792

Rev. 1/07 - DA/mc

DISASSEMBLY

1. Disconnect negative battery cable.

2. Raise and support the vehicle with two post car hoist

(recommended) or jackstands and remove both front wheels.

3. Remove both left and right inner fender wells and set

aside.

4. Disconnect and remove O2 sensors in the front of

both left and right catalytic converter, being careful not to damage.

5. Cut both left and right exhaust pipes off from

catalytic converters right at the weld

(See

Figure 1).

6. Unbolt and remove exhaust pipe from stock

manifolds.

RIGHT SIDE AND LEFT SIDE:

1. Remove the four nuts from the studs and pull off the

manifold heatshield.

2. Remove all bolts from manifold.

3. Remove manifold and gasket from vehicle through

wheel well opening.

4. Place header into position with gasket and start all

bolts, lock washers, and hardened washers. Now, tighten evenly from center out.

ASSEMBLY OF EXTENSION PIPES

1. Install both extension pipes with donut gaskets,

3/8”-16 x 2” hex bolts and lock washers supplied in kit. Make sure to locate donut gasket with equal space all around for best seal

(See Figure 2).

NOTE: Make sure to have the correct pipe on each

side of the catalytic assembly or it will not set right. I.D. number is stamped on each part: 25-9670 Left, 25-9671 - Right.

2. Align catalytic converters with extension pipes and tack weld.

3. With everything in place, complete welds around pipes.

4. Re-install O2 sensors. Use anti-seize on threads.

5. Re-connect battery and check adequate clearance of hose, wires, etc.

6. Start the vehicle and run 10-15 minutes. Then turn off and let cool.

7. Re-tighten header bolt.

FINAL INSPECTION

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

2. Re-install inner fender wells.

3. Re-install front wheels torque to factory specifications.

INSTALLATION INSTRUCTIONS

Figure 2

Figure 1

Catalytic Converter

Cut O.E.M. pipe at the weld in front

of catalytic converter

Donut Gasket

Keep equal spacing all

around connection

Side View of Extension Pipe

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