Edelbrock 66792 User manual

Catalog #66792 & 66793
©2007 Edelbrock Corporation Page 1 of 3
Brochure #63-66792
Rev. 1/07 - DA/mc
TUBULAR EXHAUST SYSTEM
For 2004-2005 Dodge Ram Pick-Up, 1500 Series,
2WD/IFS, 4WD 5.7L Hemi V8, Automatic Transmission
Catalog #66792 & 66793
INSTALLATION INSTRUCTION
Please study these instructions carefully before installing your new Tubular Exhaust System (TES). If you have any
questions, please contact our Technical Hotline at : 1-800-416-8628 from 7 am - 5pm, Monday-Friday, Pacific
Standard Time or e-mail us at [email protected].
TUBULAR EXHAUST SYSTEM: These components are designed as a system to improve the exhaust efficiency of the
Dodge 5.7L Hemi V8 engine. They are constructed of 409 HP stainless steel to better withstand the high heat present with
the fuel-injected engine, especially when used for towing or other heavy duty applications. The stainless steel used for
these systems is much more durable than mild steel, although it does not appear different in appearance. These systems
can be identified by the part numbers on each of the major components. Note that a magnet will stick to this type of
stainless steel; magnetic attraction is not a valid test for these systems. A performance gain can be expected by the
installation of the system. This system does require welding for installation (see note below) and retains all O.E.M.
emissions equipment. Not designed for vehicles with solid front axle.
Suggested Tools Needed for Installation: This vehicle has some metric fasteners.
❑ Mig welder (recommended) or gas welder - Professional welding is highly recommended.
❑3/8” rachet, sockets, standard and deep SAE and metric & 13mm stubby combo wrench with extensions and
universal 13mm and 15mm swivel sockets
❑ Combination set of open-end wrenches
❑ Hacksaw or Sawzall
❑ Jackstands, screwdrivers, pliers, crescent wrench, etc.
❑Liquid penetrant, (GM #1052627) and anti-seize compound (GM #5613695)
SPECIAL NOTICE: This Edelbrock Tubular Exhaust System has received an Executive Order number (E.O.#) from the
California Air Resources Board (C.A.R.B.) making it legal for street use in all 50 states. To assist you with emission
equipment certification, we have included a silver fan shroud decal to help testing personnel verify that this part is a legal
replacement on the vehicle for which it is cataloged. The adhesive-backed decal should be affixed next to the existing
emission and engine specifications decal. Do not cover any part of your original emission decal.
WARNING: The use of "Thermal Wrap" or any aftermarket coating process will void the warranty on your Edelbrock
Tubular Exhaust Systems. Those products can cause excessive heat and moisture buildup resulting in corrosion and
failure of the system.
IMPORTANT NOTE:
When cleaning any ceramic-coated Edelbrock T.E.S., use only soap and warm water. The use of caustic solvents (i.e.
gunks, etc.) will mar or damage the ceramic-coating.
IMPORTANT NOTE:
Proper installation is the responsibility of the installer. Improper installation will void warranty and may
result in poor performance and engine or vehicle damage.

Catalog #66792 & 66793
©2007 Edelbrock Corporation Page 2 of 3
Brochure #63-66792
Rev. 1/07 - DA/mc
DISASSEMBLY
1. Disconnect negative battery cable.
2. Raise and support the vehicle with two post car hoist
(recommended) or jackstands and remove both front
wheels.
3. Remove both left and right inner fender wells and set
aside.
4. Disconnect and remove O2 sensors in the front of
both left and right catalytic converter, being careful
not to damage.
5. Cut both left and right exhaust pipes off from
catalytic converters right at the weld
(See
Figure 1).
6. Unbolt and remove exhaust pipe from stock
manifolds.
RIGHT SIDE AND LEFT SIDE:
1. Remove the four nuts from the studs and pull off the
manifold heatshield.
2. Remove all bolts from manifold.
3. Remove manifold and gasket from vehicle through
wheel well opening.
4. Place header into position with gasket and start all
bolts, lock washers, and hardened washers. Now,
tighten evenly from center out.
ASSEMBLY OF EXTENSION PIPES
1. Install both extension pipes with donut gaskets,
3/8”-16 x 2” hex bolts and lock washers supplied in
kit. Make sure to locate donut gasket with equal
space all around for best seal
(See Figure 2).
NOTE: Make sure to have the correct pipe on each
side of the catalytic assembly or it will not set right.
I.D. number is stamped on each part: 25-9670 -
Left, 25-9671 - Right.
2. Align catalytic converters with extension pipes and
tack weld.
3. With everything in place, complete welds around
pipes.
4. Re-install O2 sensors. Use anti-seize on threads.
5. Re-connect battery and check adequate clearance
of hose, wires, etc.
6. Start the vehicle and run 10-15 minutes. Then turn
off and let cool.
7. Re-tighten header bolt.
FINAL INSPECTION
1. Check all hydraulic, vacuum and fuel lines to
ensure there is adequate clearance to T.E.S.
components.
2. Re-install inner fender wells.
3. Re-install front wheels torque to factory
specifications.
INSTALLATION INSTRUCTIONS
Figure 2
Figure 1
Catalytic Converter
Cut O.E.M. pipe at the weld in front
of catalytic converter
Donut Gasket
Keep equal spacing all
around connection
Side View of Extension Pipe

Catalog #66792 & 66793
©2007 Edelbrock Corporation Page 3 of 3
Brochure #63-66792
Rev. 1/07 - DA/mc
Edelbrock Corporation
2700 California St.
Torrance, CA 90503
Tech Line: 1-800-416-8628
E-Mail: [email protected]
KIT CONTENTS
Catalog #66792
Qty.Description
❑1 Manifold left side (#25-9378)
❑1 Manifold right side (#25-9360)
❑1 Extension Pipe Left (#25-9670)
❑1 Extension Pipe Right (#25-9671)
❑ 17 Hex header bolts
❑2 Chrysler V8 port gaskets
❑2 Donut gaskets; 2-1/4”
❑4 Hex capscrews; 3/8” x 2”
❑17 Black hardened washer; 5/16”
❑17 Lock washers; 5/16”
❑4 Lock washers; 3/8”
❑17 Lock washers; 5/16”
KIT CONTENTS
Catalog #66793
Qty.Description
❑1 Manifold left side (#25-9376)
❑1 Manifold right side (#25-9374)
❑1 Extension Pipe Left (#25-9670)
❑1 Extension Pipe Right (#25-9671)
❑17 Hex header bolts
❑2 Chrysler V8 port gaskets
❑2 Donut gaskets; 2-1/4”
❑4 Hex capscrews; 3/8” x 2”
❑17 Black hardened washer; 5/16”
❑17 Lock washers; 5/16”
❑4 Lock washers; 3/8”
❑17 Lock washers; 5/16”