97735 Monster Exhaust for 2011-2016 GM 2500/3500 6.6L Duramax
Bill of Materials
General Installation Practices
1. Before starting, familiarize yourself with the installation procedure by reading all of the instructions.
2. The exploded view (Figure 2) provides only general guidance. Refer to each step and section diagram in this manual for proper instruction.
3. Throughout this manual, the left side of the vehicle refers to the driver’s side, and the right side to the passenger’s side.
4. Disconnect the negative (ground) cable from the battery (or batteries, if there are two) before starting.
5. Route and tie wires and hoses a minimum of 6” away from exhaust heat, moving parts and sharp edges. Clearance of 8” or more is recommended where possible.
6. When raising the vehicle, support it on properly weight-rated safety stands, ramps or a commercial hoist. Follow the manufacturer’s safety precautions. Take care to balance the vehicle to prevent it from slipping or falling. When using ramps, be sure the front wheels are centered squarely on the topsides; put the transmission in park; set the hand brake; and place blocks behind the rear wheels.
Caution! Do not use floor jacks to support the vehicle while working under it. Do not raise the vehicle onto concrete blocks, masonry or any other item not intended specifically for this use.
7. During installation, keep the work area clean. Do not allow anything to be dropped into intake, exhaust, or lubrication system components while performing the installation, as foreign objects will cause immediate engine damage upon start-up.
WARNING!
Read and understand the owner’s manual before installation. Failure to do so may result in serious injury or death.
NORMAL OPERATION
Do not park, idle, or drive your vehicle on dry grass or other dry ground cover. The emission system heats up the engine compartment and exhaust system, creating a risk of fire.
The normal operating temperature of the exhaust system is very high. Never work around or attempt to repair any part of the exhaust system until it has cooled. Use special care when working around the diesel oxidation catalytic converter or diesel particulate filter. The diesel oxidation catalytic converter and the diesel particulate filter heat up to very high temperatures after only a short period of engine operation and remain hot after you switch the engine off.
Stay clear of the exhaust tailpipe after prolonged driving. Hot exhaust gasses and coming in contact with the tailpipe and/or tailpipe tip can burn you badly.
REGENERATION
Do not park or idle your vehicle over dry leaves, dry grass or other combustible materials. The regeneration process creates very high exhaust gas temperatures and the exhaust will radiate a considerable amount of heat during and after regeneration and after you have switched the engine off. This is a potential fire hazard.
The normal operating temperature of the exhaust system is very high. Never work around or attempt to repair any part of the exhaust system until it has cooled. Use special care when working around the diesel oxidation catalytic converter or diesel particulate filter. The diesel oxidation catalytic converter and the diesel particulate filter heat up to very high temperatures after only a short period of engine operation and remain hot after you switch the engine off.
Stay clear of the exhaust tailpipe during regeneration. Hot exhaust gasses and coming in contact with the tailpipe and/or the tailpipe can burn you badly.
Monster Exhaust System Installation
1. Disconnect the battery(s).
As a precaution, disconnect the ground of the battery (if there is more than one battery, disconnect both.)
Tuck the cable out of the way to prevent contact with the battery.
2. Raise the vehicle and support it with properly weight rated safety stands, ramps or a commercial hoist.
Follow the manufacturer’s safety precautions and take care to balance the vehicle to prevent it from slipping or falling.
When using ramps, be sure the front wheels are centered squarely on the ramps; place the transmission in park; set the parking brake, and place blocks behind the rear wheels.
CAUTION: DO NOT WORK UNDER ANY VEHICLE SUPPORTED ONLY BY A JACK. SEVERE INJURY MAY RESULT.
WARNING! The following step will require the use of a saw. Proper safety equipment should be used. Failure to use proper safety equipment may result in severe injury.
NOTE: Lubricating the rubber hangers with WD-40 or similar lubricant will ease the removal of the hanger pins.
3. Measure from the rear weld of the DPF toward the rear of the truck.
Take time when measuring and cutting the factory pipe to ensure the proper location and a straight cut. An improper cut will result in poor fitment.
4. Cut the factory exhaust pipe 8-27.5″ depending on truck configuration from end of the DPF.
5. Remove the factory tailpipe from the vehicle.
Disengage the exhaust system hanger pins from the rubber hangers using a large screwdriver, pry bar or hanger removal tool sold in any auto parts store.
6. Clean off any burrs left over from your cut.
7. Slide a 4” exhaust clamp onto the front of the Banks Monster Exhaust front tailpipe.
Fully engage the clamp so none of the notch is showing.
8. Install the front tailpipe onto the cut factory pipe.
Loosely snug the 4” clamp, You’ll need to adjust the angle for final fitment.
9. Fully engage the exhaust hangers.
The exhaust hangers should be parallel to the ground and the rubber bushings straight and centered.
10. Install a 5” exhaust clamp onto the inlet of the Rear Tailpipe & Install the Rear Tailpipe onto the outlet of the Front Tailpipe.
11. Insert the Rear Tailpipe hanger pin into the factory rubber hanger.
Rotate the tailpipe until the hanger pin is parallel with the frame mounted pin. Loosely snug the 5” clamp.
12. Engage the factory rubber hangers onto the hanger clamp pins.
Fully seat the Monster Exhaust towards the nose of the truck. The Rubber hangers should now be reclined slightly back, similar to how your seatbacks are.
When hot, the exhaust can grow by over an inch in length, this allows for exhaust pipe expansion.
13. Install the SideKick tip with clamp.
The tip has an internal stop to prevent it from sliding on too far. Tighten just snug so you can fine tune the tip alignment.
Make sure the drain hole is facing down, and the banks logo, facing up.
The tip should angle slightly down for condensation to drain out.
Orient the top so there is a 1″ air gap around the bodywork. Make sure the tip is slightly raked back towards the rear bumper to allow for exhaust gas siphoning.
14. Tip Adjustments:
Rotate the front and rear tail pipes until you are satisfied with the final fitment, and tighten each exhaust clamp to 50ft-lbs starting from the DPF going backwards.
15. Adjust each of the pipes to ensure that all of the hanger pins are parallel with the frame-mounted pins.
Check that the rubber hangers are all positioned slightly forward, leaning at a similar angle as your seatback.
This allows the hangers to be properly positioned once the exhaust system reaches operating temperature.
NOTICE:
The minimum distance between exhaust tip and body is one (1) inch.
CAUTION: The protective covering may ignite and burn if not removed prior to running the engine.
16. Re-connect the negative battery cable(s).
Start the engine and listen for exhaust leaks. Tighten the exhaust clamps as necessary. Whenever possible, tack weld slip connections to prevent disengagement is recommended. The Banks Monster Exhaust installation is now complete.