Edelbrock 5785 User Manual

©2005 Edelbrock Corporation
Catalog #5785

Brochure #63-0406

Rev. 6/05 - DA/mc

EDELBROCK DIESEL EXHAUST SYSTEM 

for 2002-2005 Dodge 5.9L

Quad Cab, Long & Short Bed

INSTALLATION INSTRUCTIONS

Please study these instructions carefully before installing your new Edelbrock Exhaust System.  If you have any questions or
problems, contact our 

Technical Hotline at: 1-800-416-8628 , 7am - 5pm, Monday-Friday, Pacific Standard Time or e-mail us at

edelbrock@edelbrock.com. Please fill out and mail your warranty card.

Suggested Tools for Installation:

❑

3/8" and 1/4” ratchet set and metric sockets

❑

9/16” Combo wrench

❑

Hacksaw, sawzall, chopsaw

❑

Jack and jackstands

❑

Liquid penetrant and rubber lubricant

DISASSEMBLY

1. Lift and support vehicle on correct load rated jackstand

on stable surface.

2. Unbolt I-pipe.
3. Cutting overaxle pipe at rear of muffler will make

removing muffler, overaxle, and I-pipe assembly easier,

remove muffler, I-pipe, and overaxle at this time.

ASSEMBLY

1. Install I-pipe;  Use I-pipe #25-3208 and hanger #25-4054

for short bed.  Use I-pipe #25-3206 and hanger #25-

4055 for long bed.

2. Install rear muffler hanger #23-4057 into factory

insulator.

3. Slide hanger #23-4056 over front of muffler.  The inlet

end of the muffler is the end with the number stamped on
the end cap #25-5571.  Slip muffler onto I-pipe and insert
hanger into insulator.

4. Install nut plate #23-4060 into large hole at the back of

the right side frame rail (the plate goes inside boxed

frame rail), then install tailpipe hanger #23-4059 using
supplied 7/16” bolt and washers.  Bolt will go through the
large hole in the frame rail.                      

5. Install overaxle pipe and slip into muffler.
6. Install supplied isolator onto hanger #23-4059 and install

overaxle band clamp #23-4046 to hang overaxle pipe.

7. Dual rear wheel applications require supplied tailpipe

extension (#25-3205).  Install tailpipe (#25-3204) onto
overaxle and through tailpipe hanger clamp assembly.

8. Starting at the front of the vehicle to rear, align and

tighten all clamps and hanger clamp assemblies.  Position
system for clearance around surrounding hoses, lines,

cables, and frame members for best clearance.

9. Make one final inspection for clearance around brake,

fuel lines, and wiring.  Drive vehicle and re-tighten
system.

Qty.

 Part #

Description

❑

1

25-3204

Tail pipe assembly

❑

1

25-3206

I-pipe assembly (Long Bed)

❑

1

25-3208

I-pipe assembly (Short Bed)

❑

1

25-3205

Tail pipe extension

❑

1

25-5571

Muffler assembly

❑

1

25-3207

Overaxle pipe assembly

❑

1

22-5785

Installation kit hardware

KIT CONTENTS

Edelbrock Corporation

2700 California St., Torrance, CA 90503

Tech Line: (800) 416-8628

Office: (310) 781-2222

E-Mail:  edelbrock@edelbrock.com

INSTALLATION INSTRUCTIONS