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INSTALLATION INSTRUCTIONS
Raise vehicle. See safety precautions, page 2. If
possible, support vehicle from chassis and allow
rear axle to hang.
Remove muffler and tailpipes from over rear axle.
If this assembly is to be saved intact, the vehicle
must be raised high enough so the muffler/tailpipe can
be lifted over the axle. If the tailpipes are not to be saved,
cutting the pipes will allow the assembly to be removed
more quickly.
To remove the exhaust piping from the hangers, squirt
some WD40 or similar lubricant onto the lower end of the
rubber hangers where the hanger rod protrudes through
the rubber. Now use a pry bar to pop the rubber hangers
off the rod.
Remove the intermediate pipe from between the
muffler and catalytic converter. This will be a short
stub adapter on short wheelbase models, or a pipe or pipe
with hanger on longer wheelbase vehicles.
Install the converter-to-muffler adapter onto the
catalytic converter outlet. Install a 3 x 3” adapter
on converters with a 3” outlet, or a 2
1
⁄
2
” x 3” adapter on
converters with a 2
1
⁄
2
” outlet. When the adapter is in place,
install a 2
1
⁄
2
” or 3” exhaust U-clamp to secure the adapter.
If the vehicle is a Standard Cab (not Super Cab
or Crew Cab) model, install a catalytic-converter
outlet adapter on the catalytic converter. Install a 3 x
3” adapter on converters with a 3” outlet, or a 2
1
⁄
2
x 3”
adapter on converters with a 2
1
⁄
2
” outlet. See Figure 1.
If the vehicle is anything other than the Standard
Cab 133” wheelbase model, an extension pipe
must be used between the catalytic converter and the
muffler. Vehicles with catalytic converters having a 2
1
⁄
2
”
converter outlet will require the 2
1
⁄
2
x 3” adapter and
the extension pipe. Most applications require that the
extension pipe be cut to a specific length. The following
chart lists the extension pipe and adapter requirements
for the various cab/chassis applications.
Crew Cab models use an additional hanger to
support the center of the extension pipe. A 3”
clamp/hanger is supplied with the 41” extension pipe.
Install this hanger clamp into the factory rubber hanger to
support the pipe. Do not tighten at this time.
Install the muffler onto the catalytic converter or
intermediate pipe. Hang the muffler by the front
and rear hanger clamps in the factory rubber hangers.
Leave clamps loose enough for adjustment.
Install the Stinger tailpipe over the axle and into
the muffler outlet. Insert the pin on the tailpipe
into the original factory rubber hanger.
Check the alignment of the muffler and tailpipe.
Make sure tailpipe has adequate clearance to all
chassis and suspension components (
3
⁄
4
” minimum) to
prevent rattles. When alignment looks good, tighten all
clamps.
Lower the vehicle. Remove the plastic silencer
from the engine air inlet hoses between the air
cleaner housing and the throttle body.
Using a hacksaw, remove the tapered portions
of the silencer by sawing as shown in Figure 2.
Remove any plastic shavings after cuts are completed.
Reinstall the modified silencer in the inlet air hoses.
Replace the original paper element type air
filter with the low restriction reusable K&N filter
provided. Make sure the filter is seated in the housing.
See the filter service section of these instructions for filter
maintenance and care.
Install new Banks Ram-Air filter cover using four
6mm x 40mm metric hex bolts. Tighten bolts just
enough for cover feet to contact housing base. Do not
overtighten, as this can distort cover and base. Reinstall
hoses and tighten clamps.
NOTE: All 1996 California-Only systems (P.N. 49253 &
49254) reinstall factory air filter cover.
Test drive the vehicle. Listen for any exhaust leaks
and rattles. Correct leaks and rattles by tightening
or repositioning exhaust piping as required. NOTE: The
exhaust system may smoke somewhat at first as the
grease used in the tube bending process burns off the
pipes.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Std. Cab/Long Bed
3” dia. 3 x 3” Adapter None
133” wheelbase
Std. Cab/Long Bed
2
1
/
2
” dia. 2
1
/
2
x 3” Adapter None
133” wheelbase
Super Cab/Long Bed
3” dia. Extension Pipe Cut off 13”
155” wheelbase
Super Cab/Long Bed
2
1
/
2
” dia.
Extension Pipe/
Cut off 16”
155” wheelbase 2
1
/
2
x 3” Adapter
Super Cab/Short Bed
3” dia. Extension Pipe Cut off 29”
139” wheelbase
Crew Cab/Long Bed
3” dia. Extension Pipe None
168” wheelbase
Crew Cab/Long Bed
2
1
/
2
” dia.
Extension Pipe/
Cut off 3”
168” wheelbase 2
1
/
2
x 3” Adapter
Crew Cab/Short Bed
3” dia. Extension Pipe Cut off 16”
152” wheelbase
Cat. Conv.
Cab/Chassis Outlet Size Pipe/Adapter Modification
5
13.
14.
15.
CUT OFF
TAPERED
PORTION
HERE
FIGURE 2
P.N. 96346 V.2.0