Resonator

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

Warnings

Tools required

Parts

• Exhaust resonator assembly × 1 — OEM or aftermarket resonator for 5.9L Cummins
• Exhaust clamps × 2 — Use OEM specification
• Exhaust hanger rubber isolators × 2 — Replace if cracked or deteriorated

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Allow exhaust system to cool completely if engine has been running
4. Spray all exhaust clamp bolts and hanger bolts with penetrating oil and allow to soak
5. Raise rear of vehicle with floor jack and support securely on jack stands at frame rails
6. Inspect resonator location under vehicle - typically between catalytic converter and muffler

Procedure

1. 1

   Locate and inspect resonator assembly
   Position yourself under the vehicle with adequate lighting. Locate the resonator assembly in the exhaust system between the exhaust pipe (turbo downpipe) and muffler. Inspect all clamp connections and rubber hanger mounts. Note orientation of resonator and position of hangers for reassembly.
2. 2

   Support resonator with jack or helper
   Place a floor jack with wood block under the resonator assembly to support its weight, or have a helper ready to support it during removal. This prevents the resonator from falling when disconnected and reduces strain on remaining exhaust components.
3. 3

   Remove forward exhaust clamp
   Using a 15mm socket and wrench, loosen and remove the nuts from the forward exhaust clamp connecting the resonator to the exhaust intermediate pipe. Remove the clamp completely. If clamp is severely corroded, it may need to be cut off with a sawzall or angle grinder.
   ⚠If cutting corroded clamps, protect surrounding components from sparks and debris.
4. 4

   Remove rear exhaust clamp
   Using a 15mm socket and wrench, loosen and remove the nuts from the rear exhaust clamp connecting the resonator to the muffler inlet pipe. Remove the clamp completely. Wiggle the connection slightly to break the seal between pipes.
5. 5

   Remove hanger bolts from rubber isolators
   Locate the exhaust hanger bolts securing the resonator to the rubber isolator mounts on the vehicle frame or crossmember. Use a 15mm socket to remove these bolts. Support the resonator weight with jack or helper as hangers are disconnected.
   Torque spec

   Hanger Bolts20 Nm (15 lb-ft)
6. 6

   Separate and lower resonator
   With all connections loosened, carefully separate the resonator from the forward and rear exhaust pipes. The pipes may have slight overlap - twist and pull to separate. Lower the resonator assembly carefully using the support jack or with helper assistance. Remove from under vehicle.
7. 7

   Clean mating surfaces
   Use a wire brush to clean the outside diameter of the exhaust intermediate pipe and muffler inlet pipe where they mate with the resonator. Remove all carbon buildup and rust to ensure proper sealing of new slip-fit connections.
8. 8

   Inspect and prepare rubber isolators
   Inspect the rubber exhaust hanger isolators on the vehicle frame. Replace any that are cracked, torn, or deteriorated. Clean the mounting surfaces where hanger bolts will attach.
9. 9

   Position new resonator
   Raise the new resonator assembly into position using floor jack or helper. Align the inlet end with the exhaust intermediate pipe and the outlet end with the muffler inlet pipe. Ensure proper overlap of pipes - typically 2-3 inches on each connection.
10. 10

    Install hanger bolts
    Align resonator hanger brackets with rubber isolator mounts. Install hanger bolts finger-tight to hold resonator in position. Do not fully tighten yet - allow for adjustment during clamp installation.
    Torque spec

    Hanger Bolts20 Nm (15 lb-ft)
11. 11

    Install and align exhaust clamps
    Position new exhaust clamps over both the forward and rear pipe connections. Install clamp nuts finger-tight only. Adjust resonator position to ensure proper alignment with no binding or stress on connections. Verify adequate clearance from frame, crossmembers, and driveshaft.
12. 12

    Torque exhaust clamps
    Working from front to rear, torque the exhaust clamp nuts to specification using a torque wrench. Tighten in a criss-cross pattern if clamp has multiple bolts to ensure even sealing pressure.
    Torque spec

    Exhaust Clamps55 Nm (41 lb-ft)
13. 13

    Torque hanger bolts
    With exhaust clamps secured and resonator properly aligned, torque all hanger bolts to specification. Recheck alignment and clearances after torquing.
    Torque spec

    Hanger Bolts20 Nm (15 lb-ft)

Reassembly

1. Double-check all clamp nuts and hanger bolts are torqued to specification
2. Verify adequate clearance exists between resonator and frame, driveshaft, fuel lines, and brake lines throughout full suspension travel
3. Remove jack stands and lower vehicle to ground

Verification

• Start engine and allow to idle - listen for exhaust leaks at clamp connections
• Check for unusual vibration or contact with frame components
• Perform visual inspection under vehicle while engine is running to check for leaks
• Test drive vehicle and verify no exhaust drone, rattles, or contact noises during acceleration and deceleration
• After test drive, recheck all clamp and hanger bolt torque when exhaust has cooled

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