Wake up your truck with a CORSA Performance Exhaust System for the DODGE RAM 2500 5.9L CUMMINS.
CORSA recommends that installation of this system be performed by a qualified service center or professional muffler installer who has the necessary equipment, tools and experienced personnel. However, if you decide to perform this install, the use of a hoist and an additional person will be required.
CAUTION:
Never work on a hot exhaust system. Allow time for the vehicle to cool. Always wear eye protection when working under a vehicle.
Please confirm that all parts are present before beginning the factory exhaust system removal and CORSA exhaust system installation.
Recommended Tools:
• Safety Glasses,14mm Socket,15mm Socket, Cut-Off Wheel, Grommet Pullers, Torque Wrench
Bill of Materials:
• Muffler Assembly (18DR2006), Tailpipe Assembly (18DR4025), Intermediate Pipe Assembly (18DR4028), Hydroformed Tip Assembly (16DT3005), Hardware Kit(18DR7031), Packet of Anti-Seize
Removal of Stock Cat-Back Exhaust System:
1) Using a 14mm socket loosen the nuts on the clamp just in front of the factory muffler. If the clamp
is rusted use a cut off wheel to remove the clamp.
2) Due to the clamping effects of the factory clamp the installer may need to use a cut off wheel to cut
a slot along the inlet side of the factory muffler pipe. This will make the removal of the factory muffler
easier.
3) Spray a soapy water solution at the four grommet locations shown in There is
one grommet located in front of the muffler toward the frame rail and two grommets located at the
rear of the factory muffler. The fourth grommet is the rearward most toward the spare tire. Spraying
these grommets will make the removal much easier.
4) Using grommet pullers or a similar device begin to remove the grommets from the factory hanger.
Start from the front of the factory system and work your way back. Leave the rearmost grommet
in place to support the system.
5) Now slide the complete muffler system toward the rear of the vehicle until the rear most hanger
slides out of the grommet, then move the muffler system toward the front of the truck and downward
to remove the muffler and tailpipe assembly as one unit. The removal of the stock system is
complete.
Installation of CORSA Cat-Back Exhaust System:
1) Locate the CORSA intermediate pipe assembly 18DR4028 and a 4” TORCA clamp. Slide the
intermediate pipe onto the end of the factory cat pipe and pre-tighten the TORCA clamp using a
15mm socket at this time. Final tightening will be performed after all CORSA components are prealigned.
2) Locate the CORSA muffler 15020 and a 4” TORCA clamp. Make sure that the weep hole is located
in the down position when sliding the muffler onto the intermediate pipe. Support the rear end of
the muffler with a stand type support. Pre-tighten the 4” TORCA clamp when the rear portion of the
muffler is supported.
3) Locate the tailpipe assembly 18DR4025 and a 4” TORCA clamp. From the rear of the truck slide
the inlet side of the tailpipe over the rear axle. Align the inlet of the tailpipe with the muffler exit, and
then slide the pipe assembly forward into the rear of the muffler exit. Place the factory grommets
onto the hangers and pre-tighten the TORCA clamp at this time.
NOTE:IMPORTANT:
Make sure that small drain hole in the muffler assembly faces down when installed.
4) Locate the CORSA hydro-formed tip 16DT3005 and a 4” TORCA clamp. Slide the tip onto the end of the tailpipe and pre-tighten the clamp.
5) Align the pipes to the final desired position. Use a torque wrench to tighten the TORCA clamps to 45 FT-LBS. Start from the front of the system and work toward the rear when performing the final tightening sequence.
6) It is strongly suggested that all clamps be checked and tightened after road testing the vehicle once the system has cooled.
NOTE:
During cold weather start-ups, you may experience an exhaust sound that is deeper and louder in tone than usual. This is temporary and will diminish to normal levels once your engine has reached its normal operatingtemperature.
NOTE: Immediately following the installationof your exhaust system, you may experience a trace of smokeafter initial start-up. DO NOT be alarmed. The smoke is causedby the burning of a small amount of forming oil residue used in the manufacturing process.
| This Part Fits: |
| Make |
Model |
Year |
Trim |
| DODGE |
Ram Truck |
2003 |
2500 |
| DODGE |
Ram Truck |
2004 |
2500 |
| DODGE |
Ram Truck |
2005 |
2500 |
| DODGE |
Ram Truck |
2006 |
2500 | | |
