Automotive Manual PDF

NOTE: Read all instructions before starting any work.
1. Remove the O.E. front pipe/muffler/tail pipe assembly from the vehicle. Lubricate the rubber isolators with WD-40, or a similar lubricant, to aid in removing the rod hangers. The O.E. system will not come off in one piece. Cut the system between the rear axle and the muffler. Both pieces will then come off easily.
2. Install DynoMax front intermediate pipe 54374. Insert the rod hanger into the rubber isolator on the RH frame. Finger tighten the nuts on the inlet flange connection to the converter pipe.
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Step I:
Position truck on a flat surface and lift vehicle by the frame so that the front wheels are off the ground using a floor jack and jack stands or a (2) two post lift if available.
First, remove driver side front wheel, then unbolt upper shock mounting nut.(A) Next remove lower shock mounting nut and bolt.(B) Remove shock. Install shock stem spacer provided and reinstall bushings and shock.(C) & (D) Verify that all fasteners have been tightened to the proper torque specs and reinstall wheel.
*Be sure to torque the lug nuts to the proper OEM settings.
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Step 1: Applies to H3 ONLY, for Colorado/Canyon please skip to step 2.
Position truck on a flat surface and lift vehicle by the frame so that the front wheels are off the ground using a floor jack and jack stands or a (2) two post lift if available.
First, remove driver’s side front wheel, then unbolt upper shock mounting nut. (A)
Next remove lower shock mounting nut and bolt. (B)
Remove shock. Install shock stem spacer provided and reinstall bushings and shock.
Verify that all fasteners have been tightened to the proper torque specs and re-install wheel.
*Be sure to torque the lug nuts to the proper OEM settings.
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FRONT DISASSEMBLY:
1. With vehicle on flat level ground set the emergency brake and block the rear tires. Place floor jack under the lower control arm’s front cross member and raise vehicle. Place jack stands under frame rails, behind the front wheel wells then and lower the frame onto the stands.
2. Remove both front factory skid plates located in front of and under the front differential using 15mm socket.
WARNING: Be extremely careful when loading or unloading the torsion bars; there is a tremendous amount of stored energy (load pressure) in the bars. Keep your hands and body clear of the adjuster arm assembly and puller tool in case anything slips or breaks.
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Removal of stock system:
1. Apply a penetrating lubricant liberally to all exhaust fasteners, hangers and rubber insulators.
2. Using a 15mm socket or wrench, disconnect the factory exhaust system at the four bolt flange located behind the catalytic converter. If the vehicle is not equipped with a catalytic converter disconnect the four bolt flange located approximately under the passenger side seat.
3. Remove the exhaust system from the rubber insulators and remove from under the vehicle. If a hoist is not available for use, it may be necessary to cut the tail pipe behind the muffler for removal of the system.
4. Unbolt the OEM hanger from the transmission and remove.
5. Loosen the factory band clamp and remove the stock front pipe. Some vehicles are not equipped with a catalytic converter. Do not discard the band clamp as it is required for the installation.
6. Remove the spare tire. You may not be able to reinstall your spare tire after the installation of this exhaust system.
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FRONT DISASSEMBLY:
1.With vehicle on flat level ground set the emergency brake and block the rear tires. Place floor jack under the lower control arm’s front cross member and raise vehicle. Place jack stands under frame rails, behind the front wheel wells and lower the frame onto the stands.
2. Remove both front factory skid plates located in front of and under the front differential using 15mm socket.
WARNING: Be extremely careful when loading or unloading the torsion bars; there is a tremendous amount of stored energy (load pressure) in the bars. Keep your hands and body clear of the adjuster arm assembly and puller tool in case anything slips or breaks
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Step Installation: Complete Part One, then find the section for specific instructions for your model vehicle.
Part One: Rear bracket attachment
Step 1) Attach the rear brackets to the step as shown in Figure 1, using a washer, E, and nut, I, on each stud. Tighten each nut.
Step 2) Place the cross member in position as shown in Figure 2, and secure using washers D and F, and one nut, H on each stud. Leave fasteners loose, as the bracket slots will be used to determine exact fit of rear upright bracket.
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Adjusting Lift/Leveling kit after installation
(1) Always wear proper eye protection! Position vehicle on a stable,flat surface and suspend front wheels, lifting by the frame with a floor jack or lift jack. Secure frame with jack stands. Chock tires and turn engine off prior to adjustment!
(2) Locate the two Torsion Key Adjusting Bolts in the cross member of your vehicle chassis.
(3) Using a ratchet wrench and 22mm socket,engage the Adjusting Bolt and SLOWLY turn CLOCKWISE to INCREASE ride height,or COUNTER-CLOCKWISE to DECREASE ride height. Each full turn of the Adjusting Bolt will alter ride height approximately 1/8″. Each half turn will result in a ride height change of approximately 1/16″. (4) Be sure to always check that both sides of the vehicle have been adjusted to the same ride height. Under no circumstances should this product be altered to adjust ride height beyond its design limits.
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Removal of Stock System:
1. Apply a penetrating lubricant liberally to all exhaust fasteners, hangers and rubber insulators.
2. For 2001-2005 vehicles use a 15mm socket or wrench and disconnect the factory exhaust system at the four bolt flange located behind the catalytic converter. If the vehicle is not equipped with a catalytic converter disconnect the four bolt flange located approximately under the passenger side seat. For 2006 vehicles loosen the band clamp located behind the catalytic converter.
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For Chevrolet / GMC models 2500 & 3500, model years 2001-2008, with Duramax diesel engines: Extended Cab Short and Long Bed: also Crew Cab Short and Long Bed.
Note: Each tank has the above identification designation on its top. Please check to be sure the tank is properly identified as the one to fit your truck.
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