How to Install Borla Stinger S-Type Cat-Back Exhaust - Split Side Exit on your Dodge Ram

1. Muffler assembly
2. Right tail pipe assembly
3. Left tail pipe assembly
4. Hanger/Bracket assembly (qty 2)
5. Flat washer (qty 2)
6. Rubber bracket
7. Hex head screw (qty 2)
8. Left intermediate pipe
9. 2.25” Accuseal™ clamp (qty 5)
10. Over axle pipe (qty 2)
11. 3.00” Accuseal™ clamp
12. 2003 front pipe
13. 2004 front pipe
14. 2.75” Accuseal™ clamp

Caution!!! Never work on a hot exhaust system. Serious injury in the form of burns can result If the vehicle has been in use and the exhaust system is hot, allow vehicle to cool for at least 1 hour. Always wear eye protection when working under any vehicle.

Note: It is our recommendation that you use a hoist or hydraulic lift to facilitate the installation of your new Borla Performance Cat-Back™ Exhaust System.

Taking all under car safety precautions, lift the vehicle using a hoist or hydraulic lift. Once this has been done, you may begin the removal of your old exhaust system from your vehicle.

Note: Before removing the original exhaust system from your vehicle, please compare the parts you have received with the bill of materials provided on the previous page to assure that you have all the parts necessary for the installation of your new Borla Performance Cat-Back™ Exhaust System.

Note: With a used vehicle, we suggest a penetrating spray lubricant to be applied liberally to all exhaust fasteners and allowing a significant period of time for the chemical to lubricate the threads before attempting to disassemble.

1. Unbolt clamp shown in figure 1 in front of muffler assembly.

2. Lubricate all hangers and rubber brackets.

3. Using a muffler stand or an additional person to hold the exhaust system up in place, remove the hangers from the rubber brackets. There are five total. One on the front pipe, one in the front just above the muffler assembly, two above the rear of the muffler assembly and the one shown in figure 2 securing the tail pipe.

4. Remove the exhaust system from your vehicle.

Note: With a used vehicle, we suggest a penetrating spray lubricant to be applied liberally to all exhaust fasteners and allowing a significant period of time for the chemical to lubricate the threads before attempting to disassemble.

5. Unbolt clamp shown in figure 3 just behind the front muffler assembly.

6. Lubricate all hangers and rubber brackets.

7. Using a muffler stand or an additional person to hold the rear muffler/tail pipe assembly in place, remove the hanger from the rubber bracket and remove the rear muffler/tail pipe assembly shown in figure 4 from the vehicle.

8. Unbolt the clamp shown in figure 5 located just ahead of the front muffler assembly.

9. Using a muffler stand or an additional person to hold the front muffler assembly in place, remove the hangers from the rubber brackets and remove the front muffler assembly shown in figure 6 from the vehicle.

Warning: Use extreme caution during installation. Torque all fasteners according to manufacturer’s torque values and tightening sequence. DO NOT use air impact tools to tighten fasteners on Borla Performance Exhaust Systems. Use of such tools may result in bent flanges or gasket contact areas leading to exhaust leaks. If any welding is performed, protect vehicle brake, fuel, vacuum or similar lines. Always check for any damage after welding has been done. Also check inside vehicle for damage to such items as carpet, inner liner, etc. Always have a class C fire extinguisher and a bucket of water available during any welding process.

1. Place a clamp over the expanded end of the correct front pipe assembly for your vehicle and place it into position as shown in figure 7 installing the hanger in to the rubber bracket. DO NOT tighten the clamp.

2. Place a clamp over the expanded end of the muffler assembly and set it into position as shown in figure 8 installing the hangers into the rubber brackets. DO NOT tighten the clamp.

3. Place a clamp over the expanded end of both left and right over axle pipes and set them into position as shown in figure 9. DO NOT tighten the clamp.

4. Place a clamp over the expanded end of the right tail pipe assembly and set it into position as shown in figure 10 installing the hanger into the rubber bracket. DO NOT tighten the clamp.

5. Place a clamp over the expanded end of the left intermediate pipe and place it into position as shown in figure 11. DO NOT tighten the clamp.

6. Using the hardware supplied, install hanger/bracket assembly on driver side frame rail as shown in figure 12. Install rubber bracket on to hanger/bracket assembly.

7. Place a clamp over the expanded end of left tail pipe assembly and place it into position as shown in figure 13 installing the hanger into the rubber bracket.

8. Check your exhaust system for proper clearance under the vehicle and also for tip alignment.

9. Once position has been determined to be correct, tighten the Accuseal™ clamps to 32-35 ft. lbs. working from the rear of the vehicle to the front.

10. Before starting your vehicle, make sure to check all wires, hoses, brake lines, body parts and tires for safe clearance from the exhaust system.

11. Start vehicle and check for any leaks. If any leaks are found, determine cause (such as loose or incorrectly positioned clamp) and repair as necessary.

Note: When you first start your vehicle after the installation of your new Borla Performance Exhaust System, there may be some smoke and fumes coming from the system. This is a protective oil based coating used in the manufacturing of mandrel bent performance exhaust tubing. This is not a problem and will disappear within a very short period of time after the exhaust has reached normal operating temperatures.

Congratulations!!! You have completed the installation of the world famous Borla Performance Stainless Steel Exhaust System.