S&B 6-1007 User Manual

INSTALLATION INSTRUCTIONS

P/N: 76-1007

VEHICLE APPLICATION

Year: 1998.5-02
Make: Dodge
Model: Ram 2500, 3500
Engine: 5.9L Cummins Diesel

! 24 Valve only

Please read the entire product guide before proceeding.

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Ensure all components listed on page 4 are present.

•
If you are missing any of the components, call our customer support at [phone].

•
Do not attempt to work on your vehicle while engine is hot.

•
Make sure the engine is turned off and the vehicle is in Park or the Parking Brake is set.

•

1. With the ignition switched off and the

parking brake set, disconnect the negative
battery cables on both batteries.

TOOLS REQUIRED

10mm, 13mm, 1/2” Wrench & Socket

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7/16” Deep Socket

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3/16”, 4mm, 6mm Hex Drive

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Torque Wrench (In.lb.)

•
Gasket Remover (Scraper)

•
Vacuum

•

BEFORE YOU START

2. Loosen the upper hose clamp at the OE

elbow and disconnect the hump hose from
the elbow. Note: Care should be taken not to
let any debris fall into the boost tube.

CAUTION

Use a 1/4 inch drive ratchet. NOTE: All
required torque specs. are called out in Inch
pounds NOT foot pounds!

3. Remove the bolt that secures the dip

stick tube to the elbow.

4. Pull the prong out that secures the wiring

harness to the elbow and push the harness
back away from the elbow.

7. Place the supplied Graphite Gasket (I) on

the manifold under the heater block, make
sure all four bolt holes in the gasket line up
correctly.

5. Remove the 4 bolts that secure the elbow

to the manifold and remove the elbow from
the vehicle. Careful not to let any debris fall
into the manifold. Note: If the OE bolt threads
were corroded and rust deposits have fallen
through the bolt holes into the manifold use a
vacuum to clean it out.

6. Remove both gaskets on each side of

the OE heater grid block. A scraper may be
necessary, be careful not to damage the
sealing surface and to not let any debris fall
into the manifold. You may need a vacuum at
this step as well.

8. This kit has 2 long studs (J) and 2 short studs (H), to determine the correct stud length for your

truck, thread each a long and short stud (short threaded end first) into the manifold bolt holes farthest
from the valve cover. Measure the height of the stud from the heater grid block upward. Use the
studs that are approximately 1.125” tall.

SEE EXPLODED VIEW ON PAGE 4

15461 Slover Ave., Fontana, CA 92337 - Phone: [phone] - Fax: [phone] - www.sbfilters.com

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INSTALLATION INSTRUCTIONS (Continued)

P/N: 76-1007

9. Remove the studs and place a small

amount of the supplied Thread Locker (N) to
the correct size Studs (J or H) and thread the
studs by hand into the two bolt holes farthest
from the valve cover. Stage the Socket Cap
Screws (E) by applying Thread Locker also.

Short threaded end

11. Apply a thread sealant such as Teflon

tape to each 1/8” NPT plug (G) and insert the
plugs into the ports you will not be using on
the S&B elbow. Use a 3/16 hex socket and
tighten, do not exceed 40 In. lbs.

10. Double nut a stud using the supplied Jam Nuts (K). Turning only the top nut, torque the stud to

40 In. lbs. Remove the Jam nuts and repeat process on the other stud then discard the Jam nuts.
Note: You should first place a clean shop towel in the opening of the intake manifold to prevent any
debris from falling inside.

12. Install the large end of the Silicone

hump coupler (S) over the end of the Elbow

(F) and slide the supplied T-bolt clamp (R)

over the hump coupler. Leave clamp loose
for now.

13. Place the other supplied Graphite

Gasket (I) over the Studs on top of the heater
grid block.

14. Remove the bolt at the lower dip stick

tube bracket. Place the Dip Stick Bracket (O)
(oval hole) in its place and secure loosely with
the OE bolt.

15. Place the M6 Bolt (P) through the dip

stick tube bracket and the S&B bracket (O)
and thread the M6 lock nut (Q) on the bolt,
leave loose until the upper mount is in place.

17. Install the two M8 Socket head screws (E) and M8 washers (D) through the two holes. Hand

tighten for now. If there was a ground wire connected to the elbow, place it back in the same location
between the washer and the flange of the elbow.

16. Slide the OE t-bolt clamp down the

intercooler tube. Push the silicone end of the
elbow assembly down over the intercooler
tube. Then rotate the elbow assembly over
the studs on the heater grid.

18. Place a M8 washer (D) over each stud

and thread on the M8 lock nuts (C). Torque
both the lock nuts and the screws to 145 In.
lbs. If you use a crow foot to torque the nuts,
see the crow foot calculation on page 3.

SEE EXPLODED VIEW ON PAGE 4

15461 Slover Ave., Fontana, CA 92337 - Phone: [phone] - Fax: [phone] - www.sbfilters.com

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