CORSA 2021-23 Dodge Durango Owner’s Manual
- June 9, 2024
- CORSA
Table of Contents
Dodge Durango
2021+ Hellcat 6.2L
2018+ SRT 392 SAL
Owner’s Manual
2021-23 Dodge Durango
IMPORTANT! WARRANTY AND INSTALLATION INSTRUCTIONS
Please Forward All Information to Consumer
Be sure to review the enclosed instructions prior to beginning the
installation process. If you have any questions about the enclosed parts or
instructions, or if you encounter a problem during installation:
CALL TECHNICAL SUPPORT: 440.891.0999 or 800.486.0999
TO ACTIVATE YOUR WARRANTY GO TO:
CORSAPERFORMANCE.COM/WARRANTY
COLOR INSTRUCTIONS ARE AVAILABLE BY PART NUMBER ON:
CORSAPERFORMANCE.COM
NEVER work on a hot exhaust system.
Allow time for the vehicle to cool.| Always wear eye protection when working
under a vehicle.
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INSTALL DIFFICULTY
RECOMMENDED TOOLS & SUPPLIES
• 3/8” Drive Ratchet
• 3/8” Drive 15mm Deep Socket
• Torque Wrench
• 13mm Wrench
• Safety Glasses| • 3/8” Drive 13mm Deep Socket
• Grommet Pullers
• Penetrating Lubricant Spray
• Soapy Water Solution
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PLEASE READ THESE INSTRUCTIONS BEFORE INSTALLATION.
CORSA recommends that the installation of this system be performed by a
qualified service center or professional installer who has the necessary
equipment, tools, and experienced personnel. However, if you decide to perform
this installation yourself, the use of an additional person may be required.
WARNING: Never work on a hot exhaust system. Allow time for the vehicle
to cool. Always wear eye protection when working under a vehicle.
This warranty does not extend to damaged or defect in the finish of a product
or to any product, that in the opinion of CORSA Performance, has been misused,
damaged by accident or negligence, altered or modified in any way, faulty
installation, or installed contrary to CORSA installation instructions, or
repaired by an unauthorized service facility. Full warranty available on
www.corsaperformance.com
DODGE DURANGO HELLCAT CAT BACK EXHAUST BILL OF MATERIALS – 21195 & 21196
1. Crossover Assembly (17GC4005)
2. Driver Side Axle Pipe (17GC4051)
3. Pass. Side Axle Pipe (17GC4052)
4. (21195 Only) Pass. Side Sport Tunnel Muffler (18DD2014)
5. (21195 Only) Driver Side Sport Tunnel Muffler (18DD2015)
6. Pass. Side Hellcat Rear Muffler (18DD2016)| 7. Driver Side Hellcat Rear
Muffler (18DD2017)
8. (21196 Only) Pass. Side Xtreme Head Pipe (18DD4030)
9. (21196 Only) Driver Side Xtreme Head Pipe (18DD4031)
10. Hardware Kit (18DD7014)
11. 4.5” Slash Cut Tip Assembly (Qty. of 2) (99TK3010)
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CAUTION: Never work on a hot exhaust system. Allow the vehicle to cool
for at least an hour and a half.
Always wear eye protection when working under a vehicle. It is recommended to
use cotton gloves in order to protect stainless steel surfaces from permanent
grease and oil stains.
Please confirm that all parts are present according to the bill of materials
before beginning the installation.
If something is missing call Tech Support at 440.891.099 or Toll Free:
1.800.486.0999
DODGE DURANGO 392 CAT BACK EXHAUST BILL OF MATERIALS –21197 & 21198
1. Crossover Assembly (17GC4005)
2. Driver Side Axle Pipe (17GC4051)
3. Pass. Side Axle Pipe (17GC4052)
4. (21197 Only) Pass. Side Sport Tunnel Muffler (18DD2014)
5. (21197 Only) Driver Side Sport Tunnel Muffler (18DD2015)
6. Pass. Side 392 Rear Muffler (18DD2024)| 7. Driver Side 392 Rear Muffler
(18DD2025)
8. (21198 Only) Pass. Side Xtreme Head Pipe (18DD4030)
9. (21198 Only) Driver Side Xtreme Head Pipe (18DD4031)
10. Hardware Kit (18DD7014)
11. 4.5” Slash Cut Tip Assembly (Qty. of 2) (99TK3010)
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REMOVAL INSTRUCTIONS
1. Using the ratchet and 15mm socket, loosen the clamp in front of the
passenger side flange connection.| 2. Using the 13mm wrench, loosen the two
nuts at the driver side flange location. Set aside the spring nut assemblies
to be reused during INSTALL STEP 5.
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3. Using a ratchet and a 13mm socket, remove the two bolts from each hanger
bracket at the tunnel muffler location. Set aside the four bolts to be
reused during INSTALL STEP 1. Remove the ground clip from the passenger side
front hanger of the rear muffler| 4. Using grommet pullers or similar device,
remove the front hanger grommets from both rear mufflers.
NOTE: The use of soapy water solution will aid in the removal and later
installation of the hangers in the factory grommets.
|
5. Using the ratchet and 15mm socket, loosen the clamp on the inlet pipe to
the driver side rear muffler.| 6. Remove the driver side rear muffler inlet
from the axle pipe connection.
NOTE: The use of penetrating lubricant spray on the pipe joint may aid in
removal.
|
7. Carefully remove the factory driver side muffler by pulling the rear
hanger out of the rubber grommet, then moving the muffler downward to
free it from the vehicle.| 8. The rest of the factory exhaust system will
come out in one piece. Pull the rear hanger on the passenger side rear muffler
out of the rubber
grommet and then slide the entire exhaust system down and rearwards to remove
it from the vehicle.
| 
9. Locate the factory tunnel muffler, with the factory hanger grommets and
brackets still attached.| 10. Using grommet pullers or a similar device,
remove both rubber grommets and hanger brackets from the factory tunnel
muffler.
| 
11. Using grommet pullers or a similar device, remove both rubber grommets
from the hanger brackets.| 12. Set aside the factory rubber grommets to be
reused during INSTALL STEP 3.
| 
WARNING! DO NOT SKIP THIS STEP!
It is recommended to apply the anti-seize lubricant to the threads ONLY of the
clamps and flange bolts. Failure to follow this procedure can cause nuts to
seize on clamps and potentially destroy threads.
After applying anti-seize lubricant, be sure to thoroughly clean your hands,
as lubricant will tarnish stainless steel.
All clamps should be tightened using a properly calibrated Torque Wrench.
Using an air impact gun will damage the clamp and reduce its ability to
effectively seal the joint. It may also cause the joint to separate, thereby
causing damage to your exhaust system and to your vehicle.
NOTE: Align all clamps so that the center of the clamp bolt is 90 degrees from the notch in the pipe.
INSTALLATION INSTRUCTIONS
1. Locate the two hanger assemblies provided in the hardware kit, along with
the four bolts set aside in REMOVAL STEP 3.| 2. Using a ratchet and 13mm
socket, install the passenger side hanger assembly with two of the retained
bolts at the tunnel muffler location.
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3. Locate the two factory rubber grommets set aside during REMOVAL STEP 12.
Slide one of the rubber grommets onto the hanger.
NOTE: Once again, the use of soapy water solution will aid in the installation
of the hangers into the factory grommets.| 4. Repeat INSTALL STEPS 2-4 to
install the hanger assembly on the driver side of the vehicle.
|
5. Locate the CORSA driver side tunnel muffler assembly or CORSA tunnel head
pipe assemblythe two M10-1.5X60mm bolts and two spacers from the hardware kit,
and the two factory springs nut assemblies retained in EMOVAL
STEP 2.| 6. Insert the driver side tunnel muffler/head pipe hanger into the
rubber grommet.
|
7. Insert the two supplied M10 bolts (facing forward) through the CORSA
driver side tunnel muffler/head pipe flange first, then the stock flange.
Next, slide the spacers onto the bolts from the front side, making sure they
pass
through both flanges as shown.| 8. Thread both spring nut assemblies onto the
bolts by hand. Using a ratchet with a 15mm socket and 13mm wrench, tighten the
flange hardware.
NOTE: Ensure the CORSA tunnel muffler/head pipe hanger is horizontal
while tightening the flange hardware. Tighten both sets of fasteners
evenly, ensuring that the spacers go through both flanges and are fully seated
against the bolt heads. Make sure the bolt heads are against the rear face of
the muffler flange.
|
9. Locate the CORSA passenger side tunnel muffler assembly or CORSA tunnel
head pipe assembly and one of the 2.75” clamps. Positionthe 2.75” clamp onto
the pipe inlet and then insert the passenger side tunnel uffler/head
pipe hanger into the rubber grommet.| 10. Position the CORSA passenger tunnel
muffler/head pipe inlet onto the factory cat outlet, making sure to have at
least 1.625” of overlap at the slip fit connection. Snug the clamp using a
15mm socket and ratchet, leaving it loose enough for later adjustment.
NOTE: Ensure the CORSA tunnel muffler/head pipe hanger is horizontal while
tightening the clamp.
|
11. Locate the CORSA crossover pipe assembly and two 2.75” clamps. The
crossover pipe is installed with the reinforcement brace towards the ground
and towards the rear of the vehicle.
Position the 2.75” clamps onto the inlet of the crossover pipe with the clamp
hardware facing to the inside and the clamp nuts facing down.
Install the crossover pipe inlets onto both tunnel muffler/head pipe assembly
outlet pipes.| 12. Make sure to have at least 1.625” of overlap at both slip
fit connections. Snug both clamps using a 15mm socket and ratchet, leaving
them loose enough for later adjustment.
| 
13. Locate the CORSA passenger axle pipe assembly and a 2.75” clamp. Position
the 2.75” clamp onto the axle pipe inlet, and then install the passenger axle
pipe inlet onto the passengerside outlet of the crossover assembly.| 14. Make
sure to have at least 1.625” of overlap at the slip fit connection. Snug the
clamp using a 15mm socket and ratchet, leaving it loose enough for later
adjustment.
|
15. Repeat INSTALL STEPS 13-14 to install the CORSA driver side axle pipe
onto the outlet of the driver side crossover assembly.| 16. Locate the CORSA
passenger side rear muffler assembly and one of the 2.75” clamps. Insert the
rearward hanger on the passenger side rear muffler into the rubber grommet.
|
17. Insert the forward hanger on the passenger side rear muffler into the
rubber grommet.| 18. Position the 2.75” clamp onto the inlet of the passenger
muffler assembly, with the clamp hardware facing to the outside and the clamp
nut
facing down. Install the muffler inlet onto the passenger side axle pipe
outlet. Make sure to have at least 1.625” of overlap at the slip fit
connection. Snug the clamp using a 15mm socket and ratchet, leaving it loose
enough for later adjustment.
|
19. Repeat INSTALL STEPS 16-18 to install the CORSA driver side rear muffler
assembly onto the outlet of the driver side axle pipe.| 20. Locate both CORSA
tip assemblies, and two 2.75” clamps. Position a 2,75” clamp onto one of the
tip assemblies, and install the exhaust tip onto the passenger side muffler
outlet. Adjust the position and rotation of the tip assembly until the tip is
centered in the cutout in the rear valence and the CORSA logo is positioned on
top of the tip. Repeat this step for the driver side of the vehicle.
| 
21. Reinstall the ground clip onto the passenger front hanger of the rear
muffler.| 22. Confirm at least a fingertip clearance between the exhaust
piping (in front of the rear mufflers) and the wheel sensor wiring for both
rear muffler locations. The Sensor wiring can be repositioned and adjusted (if
necessary) to create the clearance.
|
23. Confirm at least a fingertip clearance betweenthe chassis heat shield on
the passenger side(above front of rear muffler) and the top of therear muffler
case. The heat shielding materialcan be easily reshaped and adjusted (if
necessary) to create the clearance.| 
24. At this time, visually inspect the exhaust system position, tip
alignment, clamp orientation, and exhaust pipe clearance. Make any necessary
adjustments at the slip fit joints and flange connection.
25. Torque all supplied flange mounting hardware to 35 ft-lbs. at the two
flange connections.
26. With the tips held in the desired location, start at the front of the
vehicle, and tighten the nuts on the clamps. Torque all clamp nuts to 45 ft-
lbs. (61 N-m) on the 2.75” clamps.
NOTE: During cold weather start-ups, you may experience an exhaust sound
that is deeper and louder in tone than usual. This is temporary and will
diminish to normal levels once your engine has reached its normal operating
temperature.
NOTE: Immediately following the installation of your exhaust system, you
may experience a trace of smoke after initial start-up. DO NOT be alarmed. The
smoke is caused by the burning of a small amount of forming oil residue used
in the manufacturing process.
NOTE: It is strongly suggested that all clamps be checked and tightened
after road testing the vehicle once the system has cooled.
21+ Dodge Durango Hellcat 6.2L & 2018+ Dodge Durango 392 6.4L
2.75” Cat-Back Exhaust, Dual Rear Exit w/ 4.5” Slash Cut Tips
Part #: 21195 (HC Sport), 21196 (HC Xtreme), 21197 (392 Sport), 21198 (392
Xtreme)
140 Blaze Industrial Parkway, Berea, OH 44017 l P: 440.891.0999 F:
440.891.1868
[email protected] l
www.corsaperformance.com
References
- Warranty Center
- Performance Exhaust Systems | Buy Cold Air Intake Kits, High-Performance Mufflers & Headers at CORSA PERFORMANCE
- Performance Exhaust Systems | Buy Cold Air Intake Kits, High-Performance Mufflers & Headers at CORSA PERFORMANCE