Gibson 66549 User manual

INSTALLATION INSTRUCTIONS
CAT BACK STAINLESS SPLIT REAR EXHAUST
DODGE RAM 1500 TRUCK 5.7L HEMI
QUAD CAB & STANDARD CAB , SHORT BED 4DR 2/4WD
STANDARD CAB, LONG BED 2D 2WD
PART # 66549
ITEM PART # QUANTITY DESCRIPTION
A
1031-700808S
1
3” STAINLESS HEADPIPE W/HANGER
B
789800S
1
STAINLESS SUPERFLOW MUFFLER
C
1032-700812S
1
2½” STAINLESS PASSENGER SIDE TAILPIPE
D
1100-700870S
1
2½” STAINLESS DRIVER SIDE TAILPIPE
E
546-700346S
2
2½” STAINLESS EXIT PIPE
F
08269
1
10” HANGER
G
5757
5
2½” CLAMP
H
OHD300
2
3” CLAMP
I
4337
1
BAND CLAMP
J
500374
2
3½” STAINLESS TIPS
K
BO-1015
1
BOLT KIT FOR BAND CLAMP
L
M
ZIP
BO-101
2
ZIP TIES
BOLT KIT FOR HANGER
Thank you for purchasing our Gibson exhaust system for your vehicle. If you need further assistance, please do
not hesitate to call our technical dept at [phone] Monday through Friday, 8:00 am to 5:00 pm.
1

INSTALLATION INSTRUCTIONS # 66549
SUGGESTED TOOLS: ½”, 9 /16” 15 mm Wrench & Socket, WD-40, Hacksaw, Jack Stand
CAREFULLY READ INSTRUCTIONS BEFORE STARTING INSTALLATION.
When installing this exhaust system make sure to use proper safety precautions. Use jack stands when working under
the vehicle, set parking brake, block tires and use safety glasses and gloves. Allow exhaust to cool before attempting
installation. Severe injury or burns could occur if safety measures are not taken.
SUGGESTED TOOLS:
1/2”, 9/16” 15mm wrenches & sockets, WD-40, hacksaw, jack stands.
Disconnect the negative battery cable before removal of OEM exhaust. This will allow the computer to reset and recognize the
new exhaust. Lay out the exhaust on the floor so it looks like the drawing and compare parts with manual.
8. Install stainless steel tips. Clamp
down. When you have everything
in place, firmly tighten all bolts and
clamps down securely. Use
stainless steel cleaner and a Scotch
Brite pad weekly to prevent tip
from discoloration.
Inspect all fasteners after 25-50
miles of operation and re-tighten as
necessary
4. Install passenger side tailpipe
#C into muffler 1½-2”. Use clamp
#G to secure tailpipe to muffler.
DO NOT TIGHTEN. Insert
welded hanger into rubber
grommet.
5. Use the hole 19½” from the
rear of the frame to attach the 10”
hanger #F with bolt kit #M. Use
the third hole from the top on the
hanger.
6. Install driver side tailpipe #D
1½-2” into muffler and use clamp
#G to secure to muffler. Attach
clamp #G to hold up to the hanger
#F. DO NOT TIGHTEN.
7. Install exit pipes #E, use clamps
#G to secure to tailpipes. DO NOT
TIGHTEN. Roll pipes until you
have the angle you desire.
1. To remove the stock exhaust
remove it from in front of the
stock muffler. Disengage the
welded hangers using WD-40 from
the OEM rubber grommets. Do
not damage or remove the rubber
grommets as you will re-use them
to mount your new system. Now,
cut off tailpipe and remove
exhaust.
2. Install head pipe #A onto your
existing stock front pipe and
attach with clamp #H. Use a jack
stand to support the converter.
Insert welded hanger into rubber
grommet.
3. Install muffler #B onto head
pipe #A 1½”-2” with the louvers
facing towards the converter. Use
a jack stand to support the muffler.
Use clamp #H to secure the
muffler to the headpipe. Slide
band clamp #I onto muffler and
insert welded hangers into rubber
grommets. Attach with bolt kit #K.
DO NOT TIGHTEN. Muffler inlet
is looking into the louvers.
GIBSON EXHAUST systems are designed on a factory stock vehicle. Any aftermarket products installed could increase the sound levels of this Exhaust.
Make sure there is a 1” clearance from ALL rubber brake lines, shock boots, fuel lines, tires, etc to prevent heat related damage or fire.