Remove and replace the front exhaust pipe (downpipe) on a 2014 Ram 2500 with 6.7L Cummins diesel engine, connecting the turbocharger outlet to the diesel particulate filter.

Warnings

Tools required

Parts

• Front exhaust pipe (downpipe) × 1 — Use OEM specification
• Exhaust flange gasket (turbo to pipe) × 1 — Use OEM specification
• Exhaust flange gasket (pipe to DPF) × 1 — Use OEM specification
• Exhaust flange nuts/bolts × 1 — Replace if corroded
• Exhaust hanger isolators × 1 — Replace if damaged

Preparation

1. Park vehicle on level surface and apply parking brake
2. Chock rear wheels securely
3. Allow exhaust system to cool completely if recently driven (minimum 2 hours)
4. Spray all exhaust fasteners with penetrating oil and allow to soak if possible
5. Raise and secure front of vehicle on jack stands at frame rails, ensuring adequate working clearance
6. Disconnect negative battery cable to prevent codes from O2 sensor disconnection

Procedure

1. 1

   Remove heat shields
   Locate and remove the heat shields covering the front exhaust pipe. Remove bolts securing the heat shields to the transmission tunnel and frame. Set shields aside for reinstallation.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
2. 2

   Disconnect oxygen sensors
   Locate the oxygen sensors mounted in the front exhaust pipe. Disconnect electrical connectors by releasing the locking tabs. Carefully remove sensors from exhaust pipe using O2 sensor socket or 22mm wrench, turning counterclockwise. Inspect sensor threads and replace if damaged.
   ⚠O2 sensors should be removed while pipe is still warm (not hot) for easier removal. If cold, apply heat carefully with propane torch to prevent thread damage.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
3. 3

   Support front exhaust pipe
   Position floor jack or suitable support under the front exhaust pipe near the center to support weight once disconnected. Adjust height to take slight pressure off hangers without forcing pipe upward.
   ℹ️The front pipe assembly is heavy and awkward. Having an assistant is recommended for this procedure.
4. 4

   Disconnect exhaust hangers
   Locate the rubber exhaust hangers supporting the front pipe. Remove hanger bolts or carefully pry pipe loops from hanger brackets using a pry bar. Inspect rubber isolators for cracks or deterioration and replace if necessary.
   Torque spec

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

   Remove turbocharger outlet flange connection
   Locate the flange connection at the turbocharger outlet (upstream end of front pipe). Remove the exhaust flange bolts or nuts connecting the front pipe to the turbocharger. There are typically 3 bolts in a triangular pattern. Keep track of any spacers or alignment dowels.
   ⚠These fasteners are highly prone to seizing due to extreme heat. If bolts break, they must be extracted from turbocharger housing or DPF flange. Apply penetrating oil and allow to soak before attempting removal.
   Torque spec

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

   Remove DPF inlet flange connection
   Locate the flange connection at the diesel particulate filter inlet (downstream end of front pipe). Remove the flange bolts connecting the front pipe to the DPF inlet. Support the pipe as fasteners are loosened to prevent it from dropping.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
7. 7

   Remove front exhaust pipe
   With all connections disconnected, carefully lower and maneuver the front exhaust pipe from the vehicle. May require rotating and angling the pipe to clear frame rails and crossmembers. Remove and discard old flange gaskets from both turbocharger and DPF connections.
   ℹ️The pipe may have significant carbon buildup. Wear gloves and work in well-ventilated area.
8. 8

   Clean and inspect mounting surfaces
   Using a wire brush and scraper, thoroughly clean the flange mounting surfaces at both the turbocharger outlet and DPF inlet. Remove all old gasket material, carbon deposits, and corrosion. Inspect flanges for cracks, warping, or damage. Check turbocharger outlet and DPF inlet for any damage or excessive carbon buildup.
   ℹ️Do not allow debris to fall into turbocharger outlet or DPF inlet. Cover openings with shop towels during cleaning.
9. 9

   Prepare new front pipe
   Install new oxygen sensors into the new front pipe if not pre-installed. Apply a thin coat of anti-seize compound to sensor threads only (not the sensor tip). Hand-tighten sensors first, then complete with torque wrench. Install new flange gaskets at both connection points on the new pipe.
   Torque spec

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

    Install new front pipe
    With assistance, maneuver the new front pipe into position. Align the upstream flange with the turbocharger outlet and downstream flange with the DPF inlet. Insert flange bolts hand-tight at both connections. Do not fully tighten yet to allow for alignment adjustment.
    ℹ️Ensure pipe routing does not contact frame rails, crossmembers, or other components. Verify adequate clearance before tightening fasteners.
11. 11

    Align and attach exhaust hangers
    Engage the front pipe with rubber exhaust hangers. Ensure pipe sits naturally in hangers without forcing or binding. Install and hand-tighten hanger bolts. Verify pipe alignment and clearance to surrounding components before final tightening.
    Torque spec

    Hanger Bolts27 Nm (20 lb-ft)
12. 12

    Torque turbocharger flange connection
    Apply anti-seize compound to the threads of the turbocharger outlet flange bolts. Starting with the top bolt, torque the exhaust flange bolts in a cross pattern to specification. Ensure flange seats evenly and gasket does not shift during tightening.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
13. 13

    Torque DPF flange connection
    Torque the DPF inlet flange bolts in a cross pattern to specification. Work progressively, tightening in stages to ensure even gasket compression and proper sealing. Verify no gaps exist between flanges after final torquing.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
14. 14

    Connect oxygen sensors
    Connect the electrical connectors to both oxygen sensors. Ensure connectors fully seat and locking tabs engage. Route sensor wiring away from heat sources and moving components. Secure wiring with existing clips or zip ties.
    ℹ️Verify sensor connectors are firmly seated to prevent malfunction codes.
15. 15

    Reinstall heat shields
    Reinstall heat shields in reverse order of removal. Ensure shields do not contact the exhaust pipe directly and maintain proper spacing. Torque heat shield bolts to specification.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Reconnect negative battery cable
2. Lower vehicle from jack stands
3. Double-check all fasteners for proper torque
4. Verify exhaust hangers are properly seated and pipe has adequate clearance

Verification

• Start engine and listen for exhaust leaks at flange connections (will sound like ticking or hissing)
• Visually inspect both flange connections for signs of exhaust gas leakage
• Check for proper exhaust pipe clearance during idle and verify no contact with frame or body
• Use scan tool to verify oxygen sensors are communicating properly and no codes are present
• After initial warm-up, re-check flange bolt torque when system has cooled (thermal cycling may affect initial torque)
• Test drive vehicle and verify normal operation with no exhaust odors in cabin or unusual sounds

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