This procedure covers the removal and installation of the rear exhaust section on a 2014 Ram 2500 with the 6.7L Cummins diesel engine, from the intermediate pipe connection to the tailpipe.

Warnings

Tools required

Parts

• Rear exhaust section assembly × 1 — Use OEM specification
• Exhaust flange gasket × 1 — Use OEM specification
• Rubber exhaust hangers × 3 — Replace if damaged

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow exhaust system to cool completely (minimum 2 hours after operation)
3. Raise vehicle securely on jack stands at frame mounting points
4. Spray all exhaust flange bolts and hanger bolts with penetrating oil
5. Inspect work area for fuel lines, brake lines, and wiring that may interfere with exhaust removal
6. Have fire extinguisher accessible in case of unexpected hot spots

Procedure

1. 1

   Disconnect oxygen sensor (if equipped on rear section)
   Locate the downstream oxygen sensor if present on the rear exhaust section. Disconnect the electrical connector by pressing the release tab. Use a 22mm oxygen sensor socket to carefully remove the sensor from the exhaust pipe. Inspect sensor threads and bung condition.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
2. 2

   Remove heat shield (if present)
   Remove any heat shields attached to the rear exhaust section. Use appropriate socket to remove heat shield mounting bolts. Set shields aside for reinstallation or replacement.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
3. 3

   Support rear exhaust section
   Position a floor jack or support stand under the rear muffler section to prevent sudden dropping when hangers are released. Adjust height to take slight load off rubber hangers while keeping exhaust in position.
   ⚠The rear section weighs approximately 40-50 lbs. Ensure adequate support before releasing hangers.
4. 4

   Disconnect exhaust hangers
   Locate all rubber exhaust hangers supporting the rear section (typically 2-3 hangers). Use a pry bar or screwdriver to carefully work the exhaust hanger loops off the rubber isolators. Work from rear to front. Inspect rubber hangers for cracking or deterioration and replace if necessary.
   Torque spec

   Hanger Bolts27 Nm (20 lb-ft)
5. 5

   Remove flange connection bolts
   Locate the flange connection between the intermediate pipe and rear exhaust section (typically just aft of the DPF). Remove the flange bolts using an 18mm socket. There are typically 2-3 bolts. If bolts are severely corroded, apply additional penetrating oil and allow to soak, or carefully apply heat with a torch if safe to do so. Support the rear section as bolts are removed.
   ⚠Corroded bolts may snap off. If bolt breaks, the remaining stud must be extracted from the flange before reassembly.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
6. 6

   Separate flange and remove exhaust section
   With all bolts removed and hangers disconnected, carefully separate the flange connection. You may need to tap the flange lightly with a rubber mallet or use a pry bar to break the seal. Lower the rear exhaust section and maneuver it out from under the vehicle. Note the routing and position of all hangers for reinstallation.
   ⚠Watch for sharp edges on exhaust components and clearance around fuel tank and spare tire.
7. 7

   Clean flange mating surfaces
   Use a wire brush to thoroughly clean the flange mating surface on the intermediate pipe. Remove all old gasket material, carbon deposits, and corrosion. The mating surface must be flat and clean for proper seal. Inspect flange for warping or damage.
   ℹ️A warped or damaged flange will cause exhaust leaks regardless of torque specification. Replace if damage is found.
8. 8

   Prepare new exhaust section
   Unpack new rear exhaust section and verify it matches the original configuration including hanger positions and overall length. Apply anti-seize compound to all flange bolt threads. If reusing oxygen sensor, apply anti-seize to sensor threads only (avoid contact with sensor tip).
   ⚠Never apply anti-seize or any lubricant to the oxygen sensor tip or ceramic element as this will damage the sensor.
9. 9

   Install oxygen sensor (if applicable)
   If the oxygen sensor was removed, install it into the new exhaust section. Apply anti-seize to threads only. Thread sensor in by hand first, then tighten using oxygen sensor socket and torque wrench to specification.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
10. 10

    Position and support new exhaust section
    Maneuver the new rear exhaust section into position under the vehicle. Align the inlet flange with the intermediate pipe connection. Use a jack or support stand to hold the section at the correct height. Install new flange gasket between the mating surfaces.
    ℹ️Proper alignment at this stage prevents stress on hangers and ensures adequate clearance to underbody components.
11. 11

    Install flange bolts finger-tight
    Install all flange bolts with anti-seize on threads. Thread bolts in by hand initially to ensure proper thread engagement. Tighten bolts finger-tight only at this stage. Verify flange gasket is properly seated and not pinched.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
12. 12

    Install exhaust hangers
    Working from front to rear, install the exhaust hanger loops onto the rubber isolators. Use a pry bar if needed to stretch the rubber slightly. Ensure all hangers are fully seated. The exhaust should hang naturally without binding or excessive tension on any single hanger.
    ℹ️Exhaust must hang evenly with at least 1 inch clearance from frame, body, fuel tank, and driveline components throughout full suspension travel.
13. 13

    Verify clearances and alignment
    With the exhaust supported by hangers, verify proper alignment and clearance. Check that tailpipe exits properly and is not angled significantly. Verify minimum 1 inch clearance to all components. Adjust hanger positions if necessary before final torquing.
    ⚠Insufficient clearance will cause rattling, heat damage to components, and potential exhaust leaks.
14. 14

    Torque flange bolts to specification
    Using a torque wrench, tighten the flange bolts in a criss-cross pattern to the specified torque. Make multiple passes, gradually increasing torque to avoid distorting the flange. Final torque should be 64 Nm (47 lb-ft) with anti-seize applied.
    ⚠Over-torquing can warp the flange or strip threads. Under-torquing will cause exhaust leaks.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
15. 15

    Reinstall heat shields and connect sensors
    If heat shields were removed, reinstall them now using the original mounting locations. Torque heat shield bolts to specification. Reconnect the oxygen sensor electrical connector ensuring the clip fully engages.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Remove jack stands and lower vehicle to ground
2. Verify all tools and materials are removed from under vehicle
3. Check that no electrical connectors or sensors were left disconnected

Verification

• Start engine and allow to idle. Listen for any exhaust leaks at the flange connection and along the entire rear section
• Use hand near (not touching) flange joint to feel for escaping exhaust gases
• Rev engine to 2000 RPM briefly and verify no unusual vibrations or rattling sounds
• After engine reaches operating temperature, recheck all connection points for leaks
• Perform a short test drive and verify no exhaust smell in cabin, no rattling noises, and proper exhaust note
• After test drive, raise vehicle and visually inspect for any contact marks on exhaust indicating insufficient clearance
• Verify tailpipe does not have excessive black soot around flange area which would indicate a leak

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