How to Install Stainless Works 1-7/8 in. Headers w/ Off-Road Y-Pipe - Factory Connect on your Ram

Thanks for purchasing Stainless Works Muscleflow Headers 2009-2014 Dodge Ram Truck 5.7L. We have gone to great pains to make sure that our exhaust systems fit and sound great. Please follow these steps to ensure that your installation goes as planned.

1. Stainless Works recommends the use of Hi-Temp RTV sensor safe silicon gasket maker as an option to or in conjunction with the use of factory gaskets. The recommended Oxygen Sensor Safe RTV is either Valco All-in-One Aluminum or Permatex Copper P/N 101BR available at NAPA, Autozone and other retailers.

2. Disconnect the battery before starting work on the exhaust system for your vehicle. Reconnect the battery when the job is completed.

3. Your exhaust system can be installed by a weekend warrior but the use of a lift is recommended for ease of installation. If using a jack, the vehicle must be placed on a level hard surface and jack stands are required for safety reasons.

4. You will assemble the components together as specified below, but only snug the clamps as you move along from front to back. When placing the X-pipe into position, make certain that you push it fully forward and level it in with the vehicle. After aligning all the components in the vehicle, you will tighten all the clamps working from front to back of the vehicle.

5. Remove air box and air inlet pipe.

6. Remove heat shields from manifolds (8) 6mm nuts (4 per side)

7. Remove O2 sensors.

8. Disconnect exhaust from Y pipe and connection point in front of muffler (this section will not be used).

9. Remove (4) 10mm bolts (2 per side) from manifold to catalytic converters connection point.

10. Remove Y-pipe.

11. Remove 6mm bolt from dipstick and remove dipstick.

12. Remove (16) 8mm bolts (8 per side) from manifolds and remove manifolds.

13. Remove heat shields from motor mounts (they will not be reused).

14. Loosely install all lower bolts- (8) 8mm header bolts (supplied) to heads.

15. Install O2 extension now (front and rear, left and right) and tighten.

16. Install right header with (4) 8mm upper bolts and tighten.

17. When installing left header, before bolting to engine, you need to fit dipstick tube between header tubes (first and second) then install header. Note: dipstick tube may require some adjustment to properly go back in.

18. Tighten header using (3) 8mm bolts supplied for remaining top holes and (1) 8mm original bolt and dipstick spacer for front hole.

19. Install left header lead pipe using 3”clamp.

20. Install catalytic converter or offroad pipe using 3”clamp.

21. Install left intermediate pipe using 3” clamp.

22. Install right header outlet using 3” clamp.

23. Install right catalytic converter or offroad pipe using 3” clamp.

24. Install right intermediate pipe using 3” clamp and slide into the rubber hanger.

25. Re-install O2 sensors.

26. Remove second rubber hanger (it’s not used).

27. If your system fits to the factory connection point for a single exhaust, install the Y-pipe to intermediates using (2) 3” clamp.

28. If going to SW cat back remove cat back Y-pipe and install X-pipe using (2) 3” clamps.

29. Tighten and adjust from front to back.

30. Re-install airbox and piping.

31. Be sure to have adequate clearance around all wires, hoses and lines. If anything is in contact with the exhaust system, it will melt. Make sure to have at least ½” of clearance and wrap any suspect areas with DEI thermal barrier wrap.

32. After double checking for clearance and making sure all lines, wires and hoses are secured, drive the car for 10-20 miles and re-check all clamps and clearances. Your system may be tack welded at the joints/ clamps to reduce shifting of the system during heating and cooling cycles. Make certain to disconnect the battery before performing any welding.