Muffler

This procedure covers the removal and replacement of the muffler on a 1994-2007 Dodge Ram 2500 with the 5.9L Cummins diesel engine and 4WD.

Warnings

Tools required

Parts

• Muffler assembly × 1 — Use OEM specification or equivalent aftermarket
• Muffler clamps × 2 — Band-style exhaust clamps
• Rubber exhaust hangers × 2 — Replace if cracked or deteriorated

Preparation

1. Park vehicle on level ground and apply parking brake
2. Place wheel chocks behind front wheels
3. Allow exhaust system to cool completely (minimum 2 hours after operation)
4. Raise rear of vehicle with floor jack and support securely on jack stands rated for vehicle weight
5. Spray all exhaust clamp bolts and hanger bracket bolts with penetrating oil if corroded

Procedure

1. 1

   Locate and access the muffler
   Position yourself under the vehicle near the rear axle. The muffler is located behind the cab along the frame rail, typically on the passenger's side; verify actual routing on your specific vehicle before proceeding. Identify the inlet connection from the intermediate pipe, the outlet connection to the tailpipe, and the rubber hanger mounts securing the muffler to the frame.
2. 2

   Loosen inlet clamp
   Locate the band clamp connecting the intermediate pipe to the muffler inlet. Using the appropriate socket for the clamp bolt (commonly 13mm or 15mm), loosen the clamp bolt completely but do not remove. The clamp should open enough to allow pipe separation.
3. 3

   Loosen outlet clamp
   Locate the band clamp connecting the muffler outlet to the tailpipe. Using a 15mm socket, loosen the clamp bolt completely. If the clamp is severely corroded, it may need to be cut off and replaced.
4. 4

   Remove hanger bracket bolts
   Locate the rubber hanger isolators supporting the muffler. Using the appropriate socket (commonly 13mm or 15mm — verify on your vehicle), remove the bolts securing the hanger brackets to the frame. There are typically two hanger points on this muffler assembly. Support the muffler weight by hand as you remove the last bolt.
   Torque spec

   Hanger Bracket Bolts25 Nm (18 lb-ft)
5. 5

   Separate and remove muffler
   Twist and pull the muffler to separate it from the inlet and outlet pipes. The pipes may be stuck due to carbon buildup. Use a twisting motion while pulling to break the seal. Once separated, lower the muffler and remove it from under the vehicle.
6. 6

   Clean pipe connections
   Using a wire brush, clean the outside of the intermediate pipe outlet and the inside of the tailpipe inlet to remove carbon deposits and corrosion. This ensures proper seating of the new muffler and clamps.
7. 7

   Inspect rubber hangers
   Examine all rubber exhaust hangers for cracks, tears, or excessive deterioration. Replace any damaged hangers now before installing the new muffler. The diesel exhaust produces more vibration and heat which can degrade rubber faster.
8. 8

   Position new muffler
   Lift the new muffler into position and align the inlet with the intermediate pipe and outlet with the tailpipe. Insert both connections approximately 1.5-2 inches. Do not fully seat yet to allow alignment adjustment.
9. 9

   Install hanger brackets
   Align the muffler hanger isolators with the frame mounting points. Thread the hanger bracket bolts by hand to hold the muffler in position. Do not torque yet to allow for final alignment adjustment.
   Torque spec

   Hanger Bracket Bolts25 Nm (18 lb-ft)
10. 10

    Align exhaust system
    Adjust the muffler position to ensure equal insertion depth on both inlet and outlet pipes, proper clearance from the frame rail, fuel tank, driveshaft, and rear axle, and alignment with the tailpipe exit. The muffler should hang level with approximately 1 inch clearance from all components.
11. 11

    Install and tighten clamps
    Position the band clamps over the inlet and outlet connections, centered on the overlapping joint. Apply anti-seize compound to clamp bolt threads if available. Tighten both clamps to specification using a torque wrench and 15mm socket.
    Torque spec

    Muffler Clamps55 Nm (41 lb-ft)
12. 12

    Torque hanger bracket bolts
    Using a torque wrench and the appropriate socket, tighten all hanger bracket bolts to the factory-specified torque. Tighten the bolts evenly.
    Torque spec

    Hanger Bracket Bolts25 Nm (18 lb-ft)

Reassembly

1. Verify all clamps and bracket bolts are torqued to specification
2. Confirm minimum 1 inch clearance between muffler and frame, fuel tank, driveshaft, and axle through full suspension travel
3. Check that tailpipe exits cleanly without obstruction

Verification

• Lower vehicle from jack stands and remove chocks
• Start engine and listen for exhaust leaks at inlet and outlet connections (hissing or ticking sounds indicate leaks)
• With engine at idle, verify no rattles or contact between muffler and chassis components
• Perform a short test drive and re-check all connections for leaks after the exhaust system has heat cycled
• Visually inspect muffler alignment and hanger condition after first 50 miles of operation

More procedures for this vehicle