Hey guys, I'm trying to formulate a plan to construct a new exhaust for my '96 5.9L. Whoever owned this truck before me did a horrid job of making her louder. The y pipe was cut out just past the collectors on either side and straight pipes were welded in. This goes back to two cherrybombs (and is a true dual system). The O2 sensors are placed about 18" apart, one in each pipe. I don't know why I am not getting a CEL?

Anyway, I want to replace it from the headers back (most systems I've found are cat-back, and that doesn't help me). So what I need to know is what piece connects to the headers? I spent an hour today on Summit's site trying to find the correct bit to start with. I even looked at the summit brand shorty headers (they are stock replacements) and they too have the 2 bolt flange, but I can't seem to find anything that would mate up to that?

My plan is to run no cats as I am in Canada and emissions checks are rare. I would like to have dual exits just in front of the wheel on the passenger side.

Any suggestions?

Thanks

 

Being a newbie to Diesels what the heck is a CEL? As for the exhuast, keep the O2 sensors in the same place. Check Banks performance for any header OEM replacement. Look at how it is constructed. The mufflers, surprising enough glass packs are more restrictive than some flowmasters or Borla etc. If you do choose glasspack style mufflers go with Thrush & not Cherry bomb. Unless you want some back pressure - Cherry bombs are your choice between those. I am actually thinking about buying a more expensive muffler for my sisters race car than have the stupid hollowed out Cherry bomb from the dumby before that had the car prior.

Think about the pipe sizes though, if you go TOO large your velocity will slow down = BAD. Make sure your headers are know for helping torque/Hp those also effect your power obviously, but the whole system will be fun to find and use the best parts you can buy. Mandrel bends and non restrictive muffler (referring to flow) you will be fine. Gas or Diesel exhaust systems are the same when trying to make the best torque & horsepower for your dollar. Be sure to update your intake side too. I am sure others will chime in but I am all ears if you want help with this. I am always up for looking and learning any engine.

 

CEL = Check Engine Light

I am not out to extract every last pony out of this motor. Just want to replace a piece of crap exhaust system, and keeping a nice sound... I'm aiming for 2.5" piping which should be sufficient. I am not set on any type of muffler yet. Cost is a big factor for me, so that will factor in a lot of the decisions!

 

Its has been quite awhile since I have worked on the exhuast on these trucks, but if I remember right, the piping that connects the headers into a single pipe is the Y- pipe that you said had been cut out.

 

from what I've been told you do not want to get rid of your cat you will lose power. The dodge engines need a little back pressure to run right get a high flow cat like a magnaflow or something like that and from the headers you need a Y pipe down to a cat and back to your mufflers

 

Thats the answer I was fearing... as that bumps up the cost quite a bit!!

Where would be the best place to source said items?

 

if i understand it right do you need something like this? http://www.autoanything.com/exhausts...08&PID=3179975

 

Ehhh this is said over and over on vehicle forums with out much understandment. All your doing everytime you change something on the exhaust is essentially changing the "tuning" over the piping. Your torque curve will change slightly, and im mean slightly with changes in pressure. Your exhaust is only as free flowing as your restrictive link...you have stock manifolds and a 3 inch exhaust, and you have headers and a 2.5 inch, which has a better flow curve? IMO don't worry about a cat, i ,dont run one. I dont see a difference, the top end is alittle better but thats it, no change in bottom, no check engine light. Why spend $90 on a cat you dont need? just my 2 cents...
my setup is hedman headers, no cat (test pipe) and flowmaster 40, 2.5" all the way if you want to compare

 

go on ebay and for 70 bucks get yourself the a high flow cat I have had one in my truck for 2 years and it works great. just do the search high flow cat in ebaymotors. u will find them. after the cat y it off again for ur 2 pipes flowing out wherever you please. but keep a cat in it.

 

Not quite.

I will need this part to first mate up to the headers:

http://store.summitracing.com/partde...part=MPE-23285


Or: http://store.summitracing.com/partde...rt=PSM-82-1183