Challenger SRT Exhaust System swap on R/T

[RTCHAS]

Okay I couldnt find all the info else where so I will try to post up what worked for me with some pics.
Step 1. Spray all the Bolts on your ride with good penitrating oil a day ahead of project to include the O2's.
Step 2. get your parts in order (unlike me) Go to the Dealer and buy a set of SRT Exhaust bolts for the manifolds to bolt to the heads! I used GM bolts but thats another post!lol Also pick up a set of Manifold gaskets too. Total cost about $30.00. And if you want get a SRT dipstick $27.00 It bolts to the VC. The 5.7 tube bolts to the Exhaust manifold and can be bent to work, thats what I did cause no one had the SRT tube in stock.
Step 3. Get the car off the ground to work I leave this up to you be safe! You will need to jack or lift the motor up while you are doing this project so be ready for that.
Step 4. Remove the cat-back start by unbolting the D/S rear hanger and flange bolts. The other hanger's spray with lube and pull off. you can see where the left hanger is off. I unbolt the last hanger from the floor pan its just for ease of installation later.
Step 5. remove the long Pass/side pipes same way, spray where the mids and cat-back meet with lube to help remove them, get help if you can it's heavy and long!
Step 6.Now move up to the mid's or cat's. Drop booth front splash sheilds out. You will need to unplug your 02's next.
The clip @ the top of the pic gets depressed and pulled apart. Do all 4 now its not going to hurt to do the manifold 02's as well. For the Pass/side you will need to get under the hood and reach down to unplug the manifold 02 wire's.
Step 7. Unbolt your mid pipes from maniflods this should go smooth since you spayed everything down already! On the pass/side it has a heat sheild for the starter save it you will need it later.
Step 8. Now the fun starts!!! Remove the driverside motor mount by dropping the 2 bolts thru the frame and jacking up the motor via the pan with a block of wood or hoist from above.I pulled all four frame bolts to let the motor move up and down better.Once thats up take the 4 bolts out of the block and remove the mount you may need to split the bracket and mount for ease of removal by pulling the heat sheild and remove 2 bolts Driver/side mount.
Step 9. Remove manifold heatsheild .Pull the manifold bolt's and out it go's!
You now have a boat anchor to use when you go fishing ! Or a cool paper weight! this is old with the new SRT manifold
Step 10. Get your new gasket from Ma Mopar and find the D/S one they are differant put the gasket and bottom 4 bolts in place you can now slip the manifold in place and hang it on the bottom bolts while you start your top bolts.

Now if you think your able to torque these in the car, Your HIGH it's not going to happen! I tried no room. So get in with what you can stubby wrench flex socket what ever 1/4 or 3/8 drive I used it all and get them TIGHT as you can starting from the middle and working out.
Step 11. Install motor mount. I had to split it apart to reinstall it there is no room so put the bracket on the block and then lower mount in and tighten everything but the thru the frame bolts I left them out til later.Congrtas one side down!
Step 12. Pass/side Now I pulled the oil filter for room and the altenator I left it in the car just moved it aside alittle.To get more room when tightening frt flange bolts.
Now pull the motor mount and then Manifold heat sheild and dipstick tube. Next unbolt and remove the manifold! Anchor number 2!

For the install of the SRT manifold I removed the starter bolts and slide it to the side so I can tighten back to flange bolts.
Step 13. Hang your gasket and lower bolts. But wait? I see on the old manifold an extra bolt hole and none on the SRT? Yes it has one extra bolt holding the 5.7's in the front flange also you will see a port for EGR no worries in 09 5.7 dosen't use EGR. So If you want for piece of mind mark the SRT and drill the bolt hole in the SRT manifold the gasket already has the hole and it will work either way. Once you get past that hang the SRT and tighten away, but wait you didnt buy and SRT dip stick tube and are going to reuse the 5.7 tube?? Well good luck! I did it and it's a PITA. Bend bend and re-bend
Now split the mount and reinstall it throw on the Alt. and oil filter drop the motor and install all four lower mount bolts to 70ftlbs.
Step 14 remove all of you o2's and install them in the same place on your SRT mid's.Use never seize on the threads you'll thank me later.
you can now install the mids but leave them a little loose til the cat back is on. Plug in the o2's and zip tie the extra wire away from the pipes and steering shaft on D/S. On Pass/side go up under the hood and find the wire harnes with the o2 plug
you will need a razor blade and carefully cut the tape around the o2 wire's to remove it from the harnes and get a few inchs to reach the new location of the o2 plug.
Step 15. Install your cat back system and make sure to spray lube on the mids to slide them together easliy.I went with the 09 6spd system because it has smaller mufflers and a true H pipe up front.Once it is all hung in place go back and tighten the nuts on the manifolds to mids flange. Then install the starter heat sheild with some cutting around where the o2 now rest's
GOOD WORK! you now have a better breathing 5.7 with $100's of dollar's still in your Pay-pal account if you scored the SRT stuff cheap like I did. I've read SRT manifolds are good for 500hp so mod away!
Disclaimer:All information listed here is not factual, Mod @ your own risk Modding can lead to loss of funds and extreme HP addiction if you are addicted to Mod's please seek help. I expresss no responsiblity in sharing this info and if it brakes voids or blows up the car it's on you! Good Luck!

[moddog]

Nice write up Chas with pics. Let us know if you get any drone.

[RTCHAS]

Thanks Charlie! I just thru it together cause I felt the info was lacking out there. If it helps one Guy out I did my part in paying it forward. Maybe I will get some good Mopar Carma cause its be the other crappy kind lately.
I dont have the MDS turned on so i hear no drone just sweet, sweet music from the roar of a 5.7 Hemi! I went on a 1 hour run up to Gilbertsville Saturday after I finished it up. I had fun opened it up wot a few times and its sounds Nice! We also cruised @ 55 and no problem there. And I feel the difference for sure it almost, ...ALMOST.... Guys, feels like the SRT Charger did WOT on the road. Still alittle slower thou. I need to track this Pig!

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