Flowmaster AMERICAN THUNDER 817699 Service manual

409S®Stainless Steel
01/14/15
1) Raise the vehicle up on a hoist or rack to working height. If you do not
have access to a hoist or rack, raise the vehicle and support securely with jack
stands.
2) To make the removal of the stock system easier, using a hacksaw or
sawsall, cut the stock tailpipe off where it exits the muffler. Remove the
hanger at the rear of the tailpipe from the rubber mount on the vehicle and set
the tailpipe aside. This step is not mandatory, but makes removal easier.
There are retainer clips on the ends of each of the hangers that will need to
removed with pliers to allow disassembly.
3) Support the muffler with a stand and remove the two hangers at the
rear of the muffler along with the hangers in front of the muffler from the
rubber mounts on the vehicle. Then, remove the clamp on the slip connection
just behind the catalytic converter. After removing the clamp, this
connection will have to be either sliced or heated in order to separate
the connection. Remove the muffler and set aside.
4) Trim inlet pipe #26428Saccording to the following measurements
before placing onto the stock front pipe just behind the catalytic converter. Be
sure to line up the notch in the pipe with the tab on the front pipe. Place the
provided 3” clamp onto this connection and tighten enough to hold.
2014 Crew Cab, 6’-4” bed models: Trim 18.50”
2014 Crew Cab, 8’ bed models: No Trim
5) Slide clamp hanger #459HA over the back of inlet pipe #26428Sand
connect to the rubber mount on the frame located midway between the
converter and the muffler.
Pg 1 of 4 Technical Support [phone]
Installation Instructions for:
SYSTEM #817699
2014-2015 RAM 2500 SERIES TRUCK
5.7L HEMI · CREW CAB MODELS ONLY
DOES NOT FIT WITH FACTORY AIR-BAGS

6) Install clamp hanger #476HA provided in the parts kit onto the rear of
the inlet pipe and leave loose. Connect the inlet of the muffler to the back of
the inlet pipe and support the muffler with a stand. Slide the 476HA clamp
assembly over the muffler inlet and connect the hanger to the rubber mount
on the vehicle as shown, tighten the clamp enough to hold but still allow for
adjustment.
7) At the rear of the frame on the drivers side of the vehicle there is a rectangular hole in the
outside of the frame. Using this hole, connect frame hanger #474HA to the outside of the frame
using the #475HA as a backing plate on the inside of the frame, secure with the nut and washers
provided. Make sure the hanger is straight up and down, and then tighten securely. Place rubber
hanger #HA168 onto the bottom of frame hanger #474HA.
8) Install a provided 2½" clamp onto the right muffler outlet. Place the
right side tailpipe #86195Sinto position over the axle and slip into the right
side muffler outlet, while at the same time, connecting the hangers at the front
and rear of the pipe to the rubber mounts on the vehicle. Tighten the clamp
enough to hold, but still allow for adjustment.
9) Install a provided 2½" clamp onto the left muffler outlet. Place the front
section of the left side tailpipe #86194Sinto the left side muffler outlet and
connect the hanger on the pipe to the rubber mount on the vehicle. Tighten
the clamp enough to hold, but still allow for adjustment. Place a second 2½”
onto the back of this pipe in preparation for the next step.
10) Connect the rear section of the left side tailpipe #86196Sonto the back
of the front section by sliding the two sections together at the slip-fit
connection over the rear axle. Place the hanger at the rear of the tailpipe into
the rubber mount installed in Step 7 above. Tighten the clamp enough to
hold, but still allow for adjustment.
11) Slide either the side exit pipe #86197Sor the rear exit pipe #86206S
onto the ends of both over-axle pipes. Place a 2 1/2" clamp onto these slip-fit
connections. Tighten enough to hold, but still allow for adjustment. Place the
two stainless tips #ST461 onto the exit pipes and tighten the clamps enough
to hold, but still allow for adjustment. Rotate the exit pipe and tip to the
desired distance from the fender or bumper and so angle cut on tips are in the
desired location.
Pg 2 of 4 Technical Support [phone]

Adjust the position of all pipes and muffler to provide a satisfactory fit. A minimum 3/4” clearance
around all parts of the system must be maintained; while also keeping suspension travel and vibration
in mind.
Tighten all clamped connections down securely. Slide the 7/16” hanger keepers onto the end of the
hangers at the rear of the vehicle on the driver’s side to prevent the hangers from slipping out of the
rubber mounts. Use the included zip-tie to tie the rear axle breather tube up and away from the left
tailpipe to prevent damage.
For a more secure installation, we recommend welding all slip-fit connections.
PACKING LIST
Qty Description Part#
1 Inlet Pipe 26428S
1 Muffler 8530572-Z
1 Right Tailpipe 86195S
1 Left Tailpipe, Front Section 86194S
1 Left Tailpipe, Rear Section 86196S
2 Side Exit Pipe (R/L) 86197S
2 Rear Exit Pipes (R/L) 86206S
2 Stainless Tip ST461
1 Parts kit PK766
1 Frame Hanger 474HA
1 Back up plate w/bolt 475HA
1 Muffler Inlet Hanger 476HA
1 Inlet Pipe Hanger 459HA
5 2 1/2" clamp MC250BS
1 3" clamp MC300BS
1 Rubber hanger HA168
1 3/8" Nut HW103
1 3/8" lock washer HW309
1 3/8” Flat Washer HW303
2 7/16" Hanger Keepers HW502
1 8½” Nylon Zip Tie HW504
Pg 3 of 4 Technical Support [phone]

409S ® Stainless Steel
Technical Support [phone]
Installation diagram for:
SYSTEM #817699
2014 RAM 2500 SERIES TRUCK
5.7L HEMI · CREW CAB MODELS ONLY
DOES NOT FIT WITH FACTORY AIR-BAGS