aFe Large Bore-HD Polished Cat-Back - Dodge Ram 5.9L Diesel

Dodge Ram 5.9L Cummins Large Bore-HD polished cat-back

The aFe 49-42002 Large Bore-HD cat-back uses 4-inch mandrel-bent 409 stainless tubing, a free-flowing 24-inch muffler and one polished 304 stainless tip. The exact guide's stainless upper diagram controls the selected bill; no aluminized-system parts or unprinted welding process are substituted. 2004.5-2007 Dodge Ram 2500/3500 with Cummins 5.9L turbo-diesel only. The current application table labels model years 2004-2007, but the exact headline and selected guide retain the 2004.5 production cutoff: 2004 rows require the later production configuration, not blanket full-year approval. No 2003/early-2004, 6.7L, chassis-cab or other engine inference is made. Match the actual regular/Quad Cab short-bed or Quad Cab long-bed configuration and the selected short/long mid-pipe before ordering.

Key Features

• Selected aFe part 49-42002.
• 4-inch mandrel-bent 409 stainless tubing and 24-inch muffler.
• One selected polished 304 stainless tip; no unprinted outlet dimension is inferred.
• Cab/bed-specific short or long mid-pipe and original isolation mounts.
• Uses the exact selected guide's connection and tightening procedure.

Fitment

2004.5-2007 Dodge Ram 2500/3500 with Cummins 5.9L turbo-diesel only. The current application table labels model years 2004-2007, but the exact headline and selected guide retain the 2004.5 production cutoff: 2004 rows require the later production configuration, not blanket full-year approval. No 2003/early-2004, 6.7L, chassis-cab or other engine inference is made. Match the actual regular/Quad Cab short-bed or Quad Cab long-bed configuration and the selected short/long mid-pipe before ordering.

Specifications

What's Included

• The 49-42002 kit includes one selected short-wheelbase mid-pipe 05-44119 or long-wheelbase mid-pipe 05-44118, one muffler 49-91002, one one-piece over-axle/tailpipe 05-44123, two 4-inch bands 05-41042, one hanger clamp 05-41037 and one polished 304 stainless tip 49T40501-P12. Both mid-pipe alternatives are shown for configuration selection, not used together. The lower diagram is the different 49-12002 aluminized system and its 49-91001 muffler; those are not selected parts.
• The factory exhaust components outside the selected replacement sections remain; no catalyst, electronic controller, sensor, filter, wiring or fluid is added to this bill.

About aFe Power

aFe Power develops application-specific intake, filtration, exhaust, cooling, tuning, suspension, drivetrain, and truck-performance components supported by product testing and documented installation requirements.

Related Parts

• Exact selected manufacturer scope and construction
• Complete selected guide and correct parts diagram
• Full exact-part named fitment evidence
• Compare cat-back systems

FAQ

It is the selected stainless Large Bore-HD muffler-equipped cat-back for the 2004.5-2007 5.9L Cummins application, with one polished tip.

2004.5-2007 Dodge Ram 2500/3500 with Cummins 5.9L turbo-diesel only. The current application table labels model years 2004-2007, but the exact headline and selected guide retain the 2004.5 production cutoff: 2004 rows require the later production configuration, not blanket full-year approval. No 2003/early-2004, 6.7L, chassis-cab or other engine inference is made. Match the actual regular/Quad Cab short-bed or Quad Cab long-bed configuration and the selected short/long mid-pipe before ordering.

one selected short-wheelbase mid-pipe 05-44119 or long-wheelbase mid-pipe 05-44118, one muffler 49-91002, one one-piece over-axle/tailpipe 05-44123, two 4-inch bands 05-41042, one hanger clamp 05-41037 and one polished 304 stainless tip 49T40501-P12. Both mid-pipe alternatives are shown for configuration selection, not used together. The lower diagram is the different 49-12002 aluminized system and its 49-91001 muffler; those are not selected parts.

Loosen the band clamp rearward of the catalytic converter and remove original exhaust rear to front, retaining factory isolation mounts. If slip joints are stuck, the guide allows cutting original pipes for removal but prints no numeric cut reference; confirm actual removal work before cutting and retain the catalyst. Use the short mid-pipe for regular cab/Quad Cab short bed, or long mid-pipe for Quad Cab long bed. Slip the selected mid-pipe over the catalyst outlet. Install the hanger clamp with bayonet ends pointing toward the front, original rubber mounts and muffler, then the one-piece over-axle/tailpipe and selected polished tip.

Keep all clamps loose until the entire system is installed, then tighten front to rear and secure the tip. Maintain tailpipe-to-body clearance of at least 1/2 to 1 inch; retighten all parts after 50-100 miles. No numeric torque is printed; no later-system 40-45 ft-lb instruction is borrowed.

No. The selected mid-pipe slips over the existing catalyst outlet; this is a cat-back. The optional stuck-joint removal cut does not authorize deleting the catalyst.

The guide upper diagram is selected stainless with muffler 49-91002; lower 49-12002 aluminized diagram uses another muffler. Short and long mid-pipes serve different cabs/beds and are not installed together.

The primary describes a free-flowing 24-inch muffler and general flow, power, torque and EGT benefits, but no selected measured chart establishes gains or temperature reduction. No guaranteed numeric gain, fuel-economy improvement or drone-free result is established.

Installation Instructions

1. Confirm aFe 49-42002 against the exact vehicle and installed equipment. Inventory the actual components and follow the selected manufacturer instructions and current vehicle service requirements.
2. Read the full selected guide, confirm actual production/engine/body/exhaust configuration, inspect the selected packing list, cool the exhaust and safely support both vehicle and exhaust before disassembly. 2004.5-2007 Dodge Ram 2500/3500 with Cummins 5.9L turbo-diesel only. The current application table labels model years 2004-2007, but the exact headline and selected guide retain the 2004.5 production cutoff: 2004 rows require the later production configuration, not blanket full-year approval. No 2003/early-2004, 6.7L, chassis-cab or other engine inference is made. Match the actual regular/Quad Cab short-bed or Quad Cab long-bed configuration and the selected short/long mid-pipe before ordering.
3. Loosen the band clamp rearward of the catalytic converter and remove original exhaust rear to front, retaining factory isolation mounts. If slip joints are stuck, the guide allows cutting original pipes for removal but prints no numeric cut reference; confirm actual removal work before cutting and retain the catalyst. Use the short mid-pipe for regular cab/Quad Cab short bed, or long mid-pipe for Quad Cab long bed. Slip the selected mid-pipe over the catalyst outlet. Install the hanger clamp with bayonet ends pointing toward the front, original rubber mounts and muffler, then the one-piece over-axle/tailpipe and selected polished tip.
4. Keep all clamps loose until the entire system is installed, then tighten front to rear and secure the tip. Maintain tailpipe-to-body clearance of at least 1/2 to 1 inch; retighten all parts after 50-100 miles. No numeric torque is printed; no later-system 40-45 ft-lb instruction is borrowed. No battery, sensor, crossmember, ground-strap, wiring or related-product procedure is borrowed.

California Proposition 65 warning: this product can expose you to chemicals known to the State of California to cause cancer and reproductive harm.