Edelbrock 66642 User manual

Rev. 7/05 - DA/mc Page 1of 2 Catalog #66642 & #66643

Brochure #63-0429

TUBULAR EXHAUST SYSTEM

For 1997-1998 Dodge Dakota, 2&4 WD, 5.2L / 5.9L V8, Auto Transmission

1997-1998 Dodge Durango, 4WD, 5.2L / 5.9L V8, Auto Transmission

Catalog #66642, #66643

INSTALLATION INSTRUCTION

Please study these instructions carefully before installing your new Tubular Exhaust System (TES). If you have any

questions, please contact our Technical Hotline at : 1-800-416-8628 from 7 am - 5pm, Monday-Friday, Pacific

Standard Time or e-mail us at [email protected]. Please fill out and mail your warranty card.

TUBULAR EXHAUST SYSTEM: These components are designed as a system to improve the exhaust efficiency of the

Chrysler5.2Land5.9LV8engine. Theyareconstructedof409HPstainlesssteeltobetterwithstandthehighheatpresent

with the fuel-injected engine, especially when used for towing or other heavy duty applications. The stainless steel used

for these systems is much more durable than mild steel, although it does not appear different in appearance. These

systems come with a coat of black paint for good looks and protection during shipping and storage, and they can be

identified by the part numbers on each of the major components. Note that a magnet will stick to this type of stainless

steel; magnetic attraction is not a valid test for these systems. A performance gain can be expected by the installation of

the system. This system does not require welding for installation and retains all O.E.M. emissions equipment.

•Suggested Tools Needed for Installation: This vehicle has some metric fasteners.

— 3/8” ratchet socket set with extensions and universal 13mm and 15mm swivel sockets

— Combination set of open-end wrenches

— Hack saw

— Jackstands, screwdrivers, pliers, crescent wrench, etc.

— Liquid penetrant, (GM #1052627) anti-seize compound (GM #5613695)

•SPECIAL NOTICE: This Edelbrock part has received an Executive Order number (E.O. #) from the California Air

Resources Board (C.A.R.B.) making it legal for street use on pollution-controlled motor vehicles in all 50 states. To

assist you with emissions equipment certification, we have included a silver fan shroud decal to verify that this part is

a legal replacement part on the vehicle for which it is cataloged. The adhesive-backed decal should be affixed to your

fan shroud next to the existing emission and engine specification decal. Do not cover your original equipment

specification decal with the Edelbrock fan shroud decal.

•WARNING: The use of “Thermal Wrap” or any aftermarket coating process will void the warranty on your Tubular

Exhaust System. Those products can cause excessive heat and moisture buildup resulting in corrosion and early

failure of the system.

•NOTES: High temperature spark plug wires and boots are recommended to withstand head from T.E.S.

Rev. 7/05 - DA/mc Page 2of 2 Catalog #66642 & #66643

Brochure #63-0429

2. Re-install air inlet tube and air cleaner assembly.

3. Installcrossover pipe into Y-pipeassembly. Then, using

the donut gaskets and hardware supplied in kit, install

the crossover and Y-pipe assembly onto header

collectors and catalytic inet.

4. Install clamps provided onto crossover pipe and

catalytic converter and tighten.

FINAL INSPECTION

1. Check all hydraulic, vacuum and fuel lines to ensure

there is adequate clearance to T.E.S. components.

2. Re-connect battery.

3. At this point, it is a good idea to look everything over

and make sure that nothing was missed in assembly.

4. Start vehicle and bring up to normal operating

temperature. Check for possible leaks.

5. Turn engine off and let cool. Tighten all bolts again.

Catalog #66642

Qty. Description

1Manifold left side (#25-9309)

1Manifold right side (#25-9322)

1Y-Pipe (#25-9636)

1Crossover pipe - left (#25-9635)

12 Header bolts; 5/16” - 18 x 1”

12 Lock washers; 5/16”

4Lock washers; 3/8”

8Flat washers; 5/16”

4Hex capscrews; 3/8”-16 x 2”

2V8 Port gaskets

2Donut gaskets

1U-clamp; 2-1/4”

1Flange, collector

Edelbrock Corporation

2700 California St.

Torrance, CA 90503

Tech Line: 1-800-416-8628

E-Mail: [email protected]

Catalog #66643

Qty. Description

1Manifold left side (#25-9080)

1Manifold right side (#25-9114)

1Y-Pipe (#25-9636)

1Crossover pipe - left (#25-9635)

12 Header bolts; 5/16” - 18 x 1”

12 Lock washers; 5/16”

4Lock washers; 3/8”

8Flat washers; 5/16”

4Hex capscrews; 3/8”-16 x 2”

2V8 Port gaskets

2Donut gaskets

1U-clamp; 2-1/4”

1Flange, collector

INSTALLATION INSTRUCTIONS

DISASSEMBLY

1. Disconnect negative battery cable.

2. Raise vehicle and remove O2 sensor from factoryY-

pipe, careful not to damage.

3. Unbolt and remove Y-pipe assembly.

NOTE: Removing the Y-pipe from the catalytic

converter may require heating with a torch.

4. Remove air inlet tube and air cleaner assembly.

5. Remove exhaust manifolds.

6. Remove center studs from cylinder head. You will be

using the 5/16” - 18 x 1, header bolts in place of the

studs.

ASSEMBLY

1. Install T.E.S. flange gaskets and manifolds from top

along with header bolts, lock washers and flat

washers supplied. NOTE: Hardened flat washers

are to be used on slotted flange holes.

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