Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Exhaust- Monster Sport Exhaust System '03-04 - Manual (Page 8)

8
96569 v.3.0
1.
As a precaution, disconnect the
ground of the battery (if there is more
than one battery, disconnect both).
2.
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
requires 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.
3.
From under the vehicle, remove
the factory exhaust system up to
the intermediate pipe. Starting at
the rear of the vehicle, remove each
component by either cutting through
the pipe near the clamps or by
removing the clamps and heating the
joints with an oxy-acetylene torch to
allow crimped pipes to separate.
DO NOT CUT OR DAMAGE
CATALYTIC CONVERTER TUBING
DURING THE REMOVAL PROCESS.
Remove the hanger pins from the
rubber hangers with a pry bar. (Spray
lubricant will ease hanger removal.)
4.
Place a supplied 4” clamp onto
the front of the supplied intermediate
pipe. Install the intermediate pipe onto
the catalytic converter outlet or the
front intermediate pipe. Lightly snug
the exhaust clamp near the rim of the
intermediate pipe.
5.
For quad cab long bed (160.5”
wheelbase) models only: Place a
supplied 4” clamp onto the front of
the supplied extension pipe. Install
the extension pipe hanger pin into
the corresponding rubber hanger.
Connect the extension pipe onto the
intermediate pipe and loosely snug the
4” clamp.
6.
Install the front hanger clamp onto
the Monster Muffler inlet. Install the
muffler inlet onto the intermediate
pipe. With the hanger facing the rear
of the vehicle, insert the front hanger
into the vehicle’s rubber grommet.
7.
Install the rear hanger clamp onto
the Monster Muffler outlet with the
hanger pins facing forward. Install
the two (2) rear hanger pins into the
vehicle’s rubber grommets. Orient the
Banks Monster logo to be level with
the frame rail. Install a 4” clamp onto
the muffler outlet.
Monster Sport Exhaust System
Installation