Tail Pipe

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

Warnings

Tools required

Parts

• Tail pipe assembly × 1 — Verify length and exit configuration for specific model year
• Exhaust hanger insulators × 2 — Replace if cracked or deteriorated
• Exhaust flange gasket × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks at front wheels
3. Allow exhaust system to cool completely (minimum 2 hours after engine operation)
4. Raise rear of vehicle with floor jack and support securely on jack stands rated for vehicle weight
5. Apply penetrating oil to all exhaust flange bolts and hanger bolts; allow to soak for 30 minutes minimum

Procedure

1. 1

   Inspect exhaust routing and hangers
   Visually trace the tail pipe from the muffler outlet to the rear exit point. Identify all hanger points (typically 2-3 rubber insulators) and note the flange connection point at the muffler. Check condition of rubber hanger insulators and replace if cracked or torn.
2. 2

   Support tail pipe
   Position a jack stand or wooden block under the tail pipe near the muffler connection to prevent the pipe from falling when disconnected. The tail pipe may be heavier than expected and can cause injury if it drops.
3. 3

   Remove hanger bolts
   Locate the exhaust hanger brackets mounted to the frame. Remove the hanger bolts securing the rubber insulators to the frame brackets. On this vehicle, there are typically two hanger points along the tail pipe. Verify the hanger fastener size on the vehicle and use the appropriate socket to remove the hanger bolts. Note that some hangers use hook-style rods seated in rubber isolators with no bolt. If bolts are seized, apply additional penetrating oil and allow to soak.
   Torque spec

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

   Disconnect tail pipe from muffler
   Locate the connection between the muffler outlet and tail pipe inlet. This may be a bolted flange or a band/U-bolt clamp slip joint depending on the exhaust configuration. If a flanged connection is present, remove the flange bolts (verify bolt size and count on the vehicle). If a clamp is used, loosen the clamp nuts and separate the slip joint. If the joint is seized, tap gently around the flange with a rubber mallet while applying twisting pressure to break the seal. Do not pry directly on the muffler outlet pipe as this can damage the muffler.
   Torque spec

   Exhaust Flange Bolt45 Nm (33 lb-ft)
5. 5

   Remove tail pipe assembly
   With all fasteners removed, slide the tail pipe rearward to disengage from the muffler flange. Maneuver the tail pipe out from the hangers by compressing or twisting the rubber insulators. Lower the tail pipe carefully, being mindful of the spare tire and fuel tank clearance. Remove the tail pipe from under the vehicle.
6. 6

   Clean flange surfaces
   Use a wire brush to thoroughly clean the muffler outlet flange, removing all old gasket material, carbon deposits, and rust. The flange surface must be clean and flat for proper sealing. Inspect the flange for cracks or damage. Clean the threads on the flange bolt holes.
7. 7

   Inspect and prepare hanger insulators
   Check rubber hanger insulators for cracks, tears, or hardening. Replace any deteriorated insulators. If reusing insulators, clean them with a wire brush. Apply a small amount of soapy water to the inside of the insulators to ease installation of the new tail pipe hangers.
8. 8

   Install new tail pipe
   Position the new tail pipe under the vehicle and align the inlet flange with the muffler outlet flange. Install a new exhaust flange gasket between the flanges. Insert the tail pipe hangers into the rubber insulators, using soapy water as lubricant if needed. Support the tail pipe with a jack stand or block to maintain alignment.
9. 9

   Install flange bolts
   Apply anti-seize compound to the threads of the exhaust flange bolts. Install the bolts through the flange and gasket, threading them into the muffler outlet flange. Start all bolts by hand before tightening. Tighten the bolts in a cross pattern to ensure even compression of the gasket. Torque to specification using a torque wrench.
   Torque spec

   Exhaust Flange Bolt45 Nm (33 lb-ft)
10. 10

    Secure exhaust hangers
    Verify the tail pipe is properly seated in all rubber hanger insulators and that the pipe routing provides adequate clearance from the fuel tank, spare tire, and frame components (minimum 1 inch clearance recommended). Install the hanger bolts through the frame brackets and rubber insulators. Torque the hanger bolts to specification.
    Torque spec

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

    Verify tail pipe position and clearance
    Inspect the entire tail pipe routing to ensure proper clearance from all components including fuel tank, spare tire, frame rails, and suspension components. The tail pipe exit should be positioned correctly per the specific model year and bed configuration (verify exit location and side against original routing). Adjust hangers if necessary to achieve proper clearance and alignment.

Reassembly

1. Remove jack stands and lower vehicle to ground
2. Double-check all fasteners are tightened to specification
3. Verify exhaust pipe exit is properly positioned and clear of body panels

Verification

• Start engine and allow to idle while listening for exhaust leaks at the flange connection
• Check for abnormal rattling or contact noises from tail pipe hitting frame or body components
• Visually inspect flange joint and hangers while engine is running for signs of exhaust gas leakage
• Take vehicle for short test drive and re-check all connections and clearances after exhaust system reaches operating temperature
• Verify no exhaust smell in cabin and tail pipe exit is directing exhaust away from vehicle body

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