Monster sport exhaust system installation – Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Exhaust- Monster Sport Exhaust System '04-07 325 HP Dodge 5.9L HO Cummins Trucks, Including Mega Cab User Manual

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As a precaution, disconnect the

ground of the battery (if there is more

than one battery, disconnect both).

Raise the vehicle and support it with

properly weight rated safety stands,

ramps or a commercial hoist. Follow

the manufacturer’s safety precautions.

Take care to balance the vehicle to

prevent it from slipping or falling. When

using ramps, be sure the front wheels

are centered squarely on the topsides;

place the transmission in park; set the

parking brake and place blocks behind

the rear wheels.
CAuTION: DO NOT WORK uNDER

ANY VEHICLE SuPPORTED ONLY

BY A JACK. SEVERE INJuRY MAY

RESuLT.
WARNING! The following step may

require the use of a torch and/or

saw. Proper safety equipment

should be used. Failure to use

proper safety equipment may

result in severe injury.

Starting at the rear of the vehicle,

remove the tailpipe near the muffler

clamps by cutting through the

connection or by removing the clamps

and heating the joints with an oxy-

acetylene torch to allow crimped pipes

to separate. Remove the tailpipe from

the vehicle.

Remove the clamps on the catalytic

converter to the front muffler or if

applicable, the intermediate pipe

connection. TAKE CAuTION TO

NOT CuT OR DAMAGE CATALYTIC

CONVERTER TuBING DuRING THE

REMOVAL PROCESS. Separate the

muffler/ intermediate pipe to catalytic

converter connection.
Note: the use of an oxy-acetylene

torch may be necessary. Remove the

muffler hanger pins from the rubber

hangers with a pry bar (Spray lubricant

will ease hanger removal) and remove

the muffler/intermediate pipe or

muffler assembly from the vehicle.
IMPORTANT: If the vehicle

is equipped with a catalytic

converter, it should be inspected.

Diesel catalysts may become

plugged with soot and can cause

a restriction to exhaust flow,

impeding performance. Shine a

powerful flashlight into the inlet

end of the converter. Observe the

light through the other end of the

converter. The full circle of the

flashlight should be visible without

any blockage in the grid work of

the catalyst. If excessive soot is

observed, the catalyst may need

to be cleaned. TAKE PRECAuTIONS

to avoid blowing soot toward the

work area or where it could be

inhaled. ALWAYS use breathing

protection. Also inspect the

catalyst for damage (i.e. chips,

bent corners, etc.) to the grid

work. If your catalytic converter is

damaged, it may be covered under

your vehicle’s emissions warranty.

For Crew Cab Long Bed & Mega

Cab models (160.5” wheelbase)

ONLY, install a 4” exhaust clamp onto

the front of the Banks intermediate

pipe. Install the intermediate pipe onto

the catalytic converter outlet. Install

the intermediate pipe hanger onto the

corresponding rubber hanger. Loosely

snug the 4” clamp.

For all other models, Install a

4” exhaust clamp onto the front of

the Banks Extension pipe. Install the

extension pipe onto the catalytic

converter outlet. Loosely snug the 4”

clamp.

Monster Sport Exhaust System

Installation

96570 v.3.0