CAG technician Chris Boyd...
CAG technician Chris Boyd laid out the exhaust and made sure all the parts were there before beginning to remove the stock exhaust from the truck.
Sound, performance, and style were the main factors that motivated Dan Adams to choose an MBRP Pro Series 4-inch after-cat exhaust for his '06 Dodge Ram 3500 with the 5.9L Cummins. Although Dan's Mega Cab had a 4-inch exhaust from the factory, the aftermarket kit from MBRP has several advantages over the stock exhaust. The MBRP exhaust is mandrel-bent with low-degree bends to maximize exhaust flow. This means the exhaust gases can escape from the engine easier, which lowers exhaust gas temperatures and increases horsepower, torque, and fuel mileage.
The muffler that comes with the MBRP kit is significantly smaller than the stock muffler and is much less restrictive. Also, the MBRP exhaust is manufactured from mirror-polished 304 stainless steel. This material is less susceptible to corrosion than the stock steel exhaust and will likely outlast the rest of the vehicle. Dan is a professional snowmobile rider who lives in Wyoming, and his Dodge will be driven thousands of miles on roads coated with highly corrosive salt, so stainless steel was the only was to go. As for style, MBRP hit the nail right on the head for Dan. The mirror finish looks really good, and the embossed MBRP logo on the muffler is a nice touch. To finish off the kit, Dan chose a 5-inch dual-walled exhaust tip.
 Dan has no intentions of ever...  Dan has no intentions of ever removing the MBRP kit from his truck, so he gave Chris the go ahead to cut the stock system. Using a Sawzall is significantly easier than trying to unbolt the clamps that hold the exhaust pipes together, especially on trucks where the clamps and bolts have corroded. |  With the large section of...  With the large section of exhaust, including the muffler, free from the rest of the system, Chris was able to remove the hangers from the truck. This step is the most physically demanding and difficult because the hangers can be hard to remove from the rubber bushings. Since Dan's truck was still fairly new, the exhaust came free without too much trouble. On some trucks, it's necessary to spray some lubricant into the rubber bushing or use a special tool to remove the hanger from the bushing. |  With the stock exhaust completely...  With the stock exhaust completely removed from the truck, Chris began to install the new after-cat system on the vehicle. In some cases, it's easier to remove the rubber bushings from the truck and install them on the hangers before hanging the new system. |
 The rear tailpipe is removed...  The rear tailpipe is removed in a way similar to the muffler. |  The stock Dodge muffler dwarfs...  The stock Dodge muffler dwarfs the MBRP muffler in size, but there are no prizes for guessing which one is less restrictive. |  Chris installed the muffler...  Chris installed the muffler first by hanging it from the same bushings and hang points that the stock muffler used. |
We visited the guys at CAG Performance in Idaho Falls, Idaho, to witness the exhaust installation and got some tips and tricks from their master technician, Chris Boyd.
 The new tailpipe is installed...  The new tailpipe is installed and hung from a hanger next to the spare wheel. Care must be taken to correctly route the tailpipe so that it doesn't hit the shock or spare wheel. |  Chris installed the 5-inch...  Chris installed the 5-inch tip and made sure Dan was happy with its location. |  To finish off the install,...  To finish off the install, Dan applies an MBRP decal. |
 Chris installs the section...  Chris installs the section of pipe that connects the muffler to the catalytic converter. At this stage, the whole exhaust is just hanging and the pipes are connected together. It's best to make sure the exhaust is situated correctly before beginning to clamp the pipes together. |  Before installing the clamps...  Before installing the clamps on the exhaust, Chris checked that the system was hanging correctly and was not too close or touching anything on the vehicle. Four U-bolt clamps are used to secure the exhaust system together. |  This shot was taken looking...  This shot was taken looking through the rear fenderwell. The 6-inch Revtek lift kit on Dan's Dodge helps to show off the polished exhaust. |
The total install took Chris...
The total install took Chris about 40 minutes and didn't require any professional tools. Although it's easier to install an exhaust with the truck on a lift, he managed fine with a creeper on a flat concrete floor.
Keep In Mind
Dan's truck is currently running an Edge Juice module with the A2 monitor, and the MBRP exhaust has helped reduce his EGTs. Owners planning on really aggressive performance modifications-like big-horsepower electronics and injectors-would be wise to choose either a 5-inch, 6-inch, or stack exhaust system. The after-cat system does a good job of increasing performance while keeping noise levels suitable for a daily driver or tow vehicle, so it's definitely performance you can live with.