How to Install Flowmaster American Thunder Aluminized Steel Cat-Back Exhaust -Split Side/Rear Exit (02-08 4.7L RAM 1500) on your Dodge RAM

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 removal of the stock system easier, you may choose to cut the stock tailpipe off where it exits the muffler. This step is not mandatory, but makes removal easier.

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. Loosen the clamp at the muffler inlet connection. It may be necessary to slice open or heat this connection with a torch to facilitate removal. Use caution when using a torch. Remove the muffler and set aside.

1) Before installing anything, prep the clamps supplied in the hardware kit by removing the nuts, and applying a thick lubricant such as white grease or anti-seize to the threads.

2) Place the inlet pipe #TB468 in position on the front pipe from the catalytic converter and install the 3” clamp #MC300G proved in the parts kit.

3) Connect the inlet of the muffler #530552 to the inlet pipe. Use a stand to support the muffler and install clamps on inlet and outlet necks, but do not tighten yet.

4) At the rear of the frame on the drivers side of the vehicle (next to spare tire) there is an oversized slotted hole that goes through both sides of the frame. Using this hole, connect frame hanger #226HA to the frame using the 3/8” x 4” bolt, nut, washer and the #HA566 as a backing plate on both sides of the frame. Make sure the hanger is straight up and down, tighten securely.

5) Place rubber hanger #HA168 onto the bottom of frame hanger #226HA.

6) Place right side tailpipe #16517 into position over the axle and slip into the right side muffler outlet. Connect the hangers at the front and rear of the pipe to the rubber mounts on the vehicle. Tighten clamp enough to hold, but still allow for adjustment.

7) Place the front section of the left side tailpipe #16518 into the left side muffler outlet and connect the hanger on the pipe to the rubber mount on the frame. Tighten clamp enough to hold, but still allow for adjustment.

8) Connect the rear section of the left side tailpipe #16520 onto 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 pipe into the rubber mount installed in Step 5 above. Install a provided 2 1/2" clamp onto the over-axle slip-fit connection and tighten enough to hold, but still allow for adjustment.

9) Slide rear exit pipes #16397 or side exit pipes #16317 onto the ends of both over-axle pipes. Place a provided 2 1/2" clamp onto these slip-fit connections. Place the two stainless tips 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 position.

10) Adjust the position of all muffler, pipes and tips to provide a satisfactory fit. Maintain a minimum of 3/4" clearance between the Flowmaster system, the drivetrain and chassis components, while also keeping suspension travel and vibration in mind.

11) Tighten down all clamped connections securely. After the system is secure, slide the 7/16” hanger keepers onto the end of the hangers a the rear of the vehicle on the driver side. This will prevent the hangers from slipping out of the rubber mounts.

12) For a cleaner appearance and more secure installation, we highly recommend welding all slipfit connections. If you live in a geographical area that has harsh winters or sees a great deal of precipitation, the use of high temperature paint over the welded areas can help to prevent surface rust and premature corrosion.