S&B 76-1004 User Manual

INSTALLATION INSTRUCTIONS

P/N: 76-1004

VEHICLE APPLICATION

Year: 2003-07
Make: Dodge
Model: Ram 2500, 3500
Engine: 5.9L Cummins Diesel

Please read the entire product guide before proceeding.

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Ensure all components listed on page 4 are present.

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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.

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

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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” & 6mm Hex Drive

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Torque Wrench (In.lb.)

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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. Remove the lock nut and 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 the screw that secures the

ground wire to the manifold to gain access
and to remove both gaskets. 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”.

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: 76-1004

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 use 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 hose (O) over the end of the Elbow (F)
and secure using the supplied T-bolt clamp

(P). Torque the clamp to 90 In. lbs.

13. Place the other supplied Gasket (I)

over the Studs on top of the heater grid block.

14. Remove the OE nut at the lower dip

stick tube bracket and carefully push the tube
back about one inch.

15. 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.

17. 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. If there was a ground wire connected to the manifold, place it back in the
same location.

16. Install the two M8 Socket head screws

(E) and M8 washers (D) through the two

holes . Hand tighten for now.

18. Slide the OE t-bolt clamp up onto the

Silicone adapter (O) and torque the clamp to
90 In. lbs.

SEE EXPLODED VIEW ON PAGE 4

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

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