©2005 Edelbrock Corporation
Catalog #5785 Brochure #63-0406
Rev. 6/05 - DA/mc
EDELBROCK DIESEL EXHAUST SYSTEM
for 2002-2005 Dodge 5.9L
Quad Cab, Long & Short Bed
Catalog #5785
INSTALLATION INSTRUCTIONS
Please study these instructions carefully before installing your new Edelbrock Exhaust System. If you have any questions or
problems, contact ourTechnical Hotline at: 1-800-416-8628, 7am - 5pm, Monday-Friday, Pacific Standard Time or e-mail us at
Suggested Tools for Installation:
❑3/8" and 1/4” ratchet set and metric sockets ❑9/16” Combo wrench
❑Hacksaw, sawzall, chopsaw ❑Jack and jackstands
❑Liquid penetrant and rubber lubricant
DISASSEMBLY
1. Lift and support vehicle on correct load rated jackstand
on stable surface.
2. Unbolt I-pipe.
3. Cutting overaxle pipe at rear of muffler will make
removing muffler, overaxle, and I-pipe assembly easier,
remove muffler, I-pipe, and overaxle at this time.
ASSEMBLY
1. InstallI-pipe; UseI-pipe#25-3208andhanger#25-4054
for short bed. Use I-pipe #25-3206 and hanger #25-
4055 for long bed.
2. Install rear muffler hanger #23-4057 into factory
insulator.
3. Slide hanger #23-4056 over front of muffler. The inlet
endofthemuffleristheendwiththenumberstampedon
theendcap#25-5571. SlipmufflerontoI-pipeandinsert
hanger into insulator.
4. Install nut plate #23-4060 into large hole at the back of
the right side frame rail (the plate goes inside boxed
frame rail), then install tailpipe hanger #23-4059 using
supplied 7/16” bolt and washers. Bolt will go through the
large hole in the frame rail.
5. Install overaxle pipe and slip into muffler.
6. Install supplied isolator onto hanger #23-4059 and install
overaxle band clamp #23-4046 to hang overaxle pipe.
7. Dual rear wheel applications require supplied tailpipe
extension (#25-3205). Install tailpipe (#25-3204) onto
overaxle and through tailpipe hanger clamp assembly.
8. Starting at the front of the vehicle to rear, align and
tightenall clamps andhanger clamp assemblies. Position
system for clearance around surrounding hoses, lines,
cables, and frame members for best clearance.
9. Make one final inspection for clearance around brake,
fuel lines, and wiring. Drive vehicle and re-tighten
system.
WARNING!!!
Exhaust gas contains carbon monoxide,
a deadly invisible gas.
Correct any leaks before driving!
Qty. Part # Description
❑125-3204 Tail pipe assembly
❑125-3206 I-pipe assembly (Long Bed)
❑125-3208 I-pipe assembly (Short Bed)
❑125-3205 Tail pipe extension
❑125-5571 Muffler assembly
❑125-3207 Overaxle pipe assembly
❑122-5785 Installation kit hardware
KIT CONTENTS
Edelbrock Corporation
2700 California St., Torrance, CA 90503
Tech Line: (800) 416-8628
Office: (310) 781-2222
INSTALLATION INSTRUCTIONS
