Owners manual

Installation Instructions
2841 W. Clarendon ● Phoenix, AZ 85017 ● Phone [phone] ● Fax [phone]
http://www.pacesetterexhaust.com
#70-2211 #72C2211 03-07 Dodge RAM 1500 (exc. Mega Cab), 2/4WD, 5.7L HEMI, Long Tube
Before installation, read and make sure you understand all instructions, and have the necessary equipment.
WARNING: Before working on the vehicle, make sure that it is well supported by jack stands or ramps of
sufficient load capacity for the weight of the vehicle. NEVER work on any vehicle which is supported only by
its service jack.
1. Disconnect battery
2. Raise vehicle on lift (preferred), or on jack stands or ramps.
3. All work on this installation can be done from underneath the truck.
4. Disconnect electrical connections to all four O2 sensors, and remove sensors. Label sensors with masking tape.
They are different, front and rear. The wire harnesses for the front sensors (pre-cat) will need to be lengthened. See
separate instructions for doing this.
5. Loosen clamp holding Y-Pipe to intermediate pipe. Slide exhaust system rearward to disconnect from Y-Pipe. *On
4WD vehicles, remove evap. canister assembly.
6. Loosen clamp at Y-pipe center joint and cut tack weld. Unbolt Y-Pipe at manifold flanges and remove Y-pipe one
side at a time. Or, on 2WD vehicles, Support transmission and remove crossmember, remove Y-pipe in one piece.
*On 4WD vehicles, Y-pipe must be separated at center joint, and driveshaft removed.
7. Remove exhaust manifolds. Clean gasket surfaces on heads.
8. There are locating tabs welded to the upper control arm bolts. The one on the right rear upper control arm bolt will
conflict with the new header. It can be bent forward about 45 degrees, or cut off to provide clearance.
9. On ‘06 vehicles, the fuel line must be bent upward to ensure adequate clearance. Remove the fuel line from the
chassis clip, bend upwards and reinstall. The vent hoses can then be zip tied to the fuel line. This group should then
be wrapped with supplied heat shielding material.
10. *On 4WD vehicles only, disengage all trans cooler line clips. Remove cooler lines from transmission and plug.
Lines can be moved down and out of the way. The cooler lines should be re-installed after the header is in place, but
before it is bolted up to head.
11. When installing new headers, use header gaskets included in kit, and apply a thin coat of O2 sensor safe high
temperature gasket sealer (such as Permatex Ultra-Copper) around exhaust port holes, both sides of gasket.
12. Install headers with new header bolts included in kit. Torque bolts in stages and from center to outside. Final
torque should be 18 ft lbs.
13. Install Off Road Y-pipe, part number 82-1187 per instructions included with Y-pipe.
14. Re-install O2 sensors after extending the wire harnesses.
15. If vehicle is equipped with automatic transmission, Install heat shielding material around shifter cable where it
comes closest to header tubes. You can either detach cable from bracket and slide heat shield over cable, or split
heat shield with shears and wrap around cable. Clamp in place so that ends extend beyond the closest header tubes.
Install heat shield around lower trans cooler line also.
16. *On 4WD vehicles, re-install evap cannister. Remove vehicle from stands, reconnect battery. Start engine and
check for exhaust leaks and rattles. Listen or watch for clearance issues. Test drive.
It is recommended that all header bolts and exhaust system clamps be re-torqued after the first hot-cold
cycle, and periodically thereafter. Due to the lubricants used in the mandrel bending process, some smoke
may be seen on initial startup. This is normal and not harmful. It will disappear as the lubricant burns off.