Exhaust Tip

This procedure covers the removal and installation of the exhaust tip on a 1994-2007 Dodge Ram 2500 with the 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Exhaust tip (aftermarket or OEM replacement) × 1 — Use desired style - clamp-on or bolt-on
• Exhaust clamp (if clamp-on style) × 1 — Match tip diameter

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks at front wheels to prevent rolling
3. Allow exhaust system to cool completely if vehicle was recently driven (minimum 1 hour)
4. Raise rear of vehicle with floor jack and support securely on jack stands under frame rails
5. Spray all exhaust clamp bolts and hanger bolts with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Access the exhaust tip
   Position yourself under the rear of the vehicle where the exhaust tip exits. Inspect the mounting method - it will either be a clamp-on style secured with a band clamp around the tailpipe, or a bolt-on style secured to an exhaust hanger bracket. Verify the exhaust system is cool to the touch.
2. 2

   Remove clamp-on exhaust tip (if applicable)
   If your tip uses a band clamp: Use a 13mm socket to loosen the clamp bolt completely. Do not remove the bolt entirely - loosen it until the clamp opens. Twist the exhaust tip slightly back and forth while pulling rearward to break it free from the tailpipe. The tip should slide off once the clamp is sufficiently loosened. If stubborn, apply more penetrating oil and wait.
3. 3

   Remove bolt-on exhaust tip (if applicable)
   If your tip bolts to a hanger bracket: Locate the mounting bolts securing the tip to the exhaust hanger bracket (typically two bolts). Use a 13mm or 15mm socket (depending on hardware) to remove these bolts completely. Support the exhaust tip as you remove the final bolt to prevent it from falling. Remove the tip from the vehicle.
   Torque spec

   Hanger Bolts20 Nm (15 lb-ft)
4. 4

   Clean mounting surfaces
   Use a wire brush to clean the tailpipe end (for clamp-on style) or the exhaust hanger bracket mounting surface (for bolt-on style). Remove all rust, carbon buildup, and old gasket material. For clamp-on installations, ensure the tailpipe outer diameter is clean and smooth for proper seal. Wipe clean with a rag.
5. 5

   Inspect exhaust system condition
   While underneath the vehicle, inspect the visible exhaust system components for damage, excessive rust, or loose hangers. Check that the tailpipe is secure and not damaged at the mounting point. If significant corrosion or damage is present, address these issues before installing the new tip.
6. 6

   Prepare new exhaust tip
   Unpack the new exhaust tip and verify it matches the required diameter and mounting style. For clamp-on tips, ensure the clamp is loosened completely. For bolt-on tips, apply a thin coat of anti-seize compound to the bolt threads. If the tip includes mounting hardware, verify all pieces are present.
7. 7

   Install clamp-on exhaust tip (if applicable)
   For clamp-on style: Slide the new tip onto the tailpipe, ensuring it seats fully and is positioned at the desired depth and angle. The tip should slide on 2-3 inches minimum. Position the clamp over the connection point and hand-tighten the clamp bolt. Adjust the tip angle and rotation to achieve desired appearance, then tighten the clamp bolt securely with a 13mm socket. Do not overtighten as this can deform the pipe.
8. 8

   Install bolt-on exhaust tip (if applicable)
   For bolt-on style: Position the new tip onto the exhaust hanger bracket, aligning the mounting holes. Insert the mounting bolts and start them by hand to ensure proper thread engagement. Hand-tighten both bolts, then use a torque wrench to tighten to specification in a cross pattern if multiple bolts are present.
   Torque spec

   Hanger Bolts20 Nm (15 lb-ft)
9. 9

   Verify tip alignment and clearance
   Check that the exhaust tip is properly aligned and positioned at the desired angle. Verify adequate clearance between the tip and the rear bumper, hitch (if equipped), or body panels. The tip should not contact any vehicle components. Adjust as needed before final tightening. For clamp-on tips, you may need to loosen and reposition.

Reassembly

1. Perform a final visual inspection of the exhaust tip installation to ensure proper alignment and secure mounting
2. Verify all clamps or bolts are tight and properly torqued
3. Lower vehicle from jack stands and remove wheel chocks

Verification

• Start the engine and check for exhaust leaks at the tip connection point - there should be no hissing or visible exhaust escaping from the joint
• Listen for rattling or vibration noises that would indicate loose mounting
• Visually inspect tip alignment from behind the vehicle - it should be centered in the bumper cutout and at the desired angle
• After initial test drive, re-check clamp or mounting bolts for tightness as thermal cycling may cause slight loosening

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