Remove and replace the intermediate exhaust pipe on a 2014 Ram 2500 with 6.7L Cummins diesel engine, including oxygen sensor transfer and exhaust hanger service.

Warnings

Tools required

Parts

• Intermediate exhaust pipe × 1 — Use OEM specification
• Exhaust flange gasket (forward) × 1 — Use OEM specification
• Exhaust flange gasket (rear) × 1 — Use OEM specification
• Exhaust hanger insulators (if worn) × 2 — Use OEM specification
• Anti-seize compound (nickel-based) × 1 — High temperature rated

Preparation

1. Park vehicle on level surface and apply parking brake
2. Allow exhaust system to cool completely (minimum 2 hours after engine operation)
3. Raise vehicle using floor jack and support securely on jack stands at frame rails
4. Spray all exhaust flange bolts, hanger bolts, and oxygen sensor with penetrating lubricant
5. Inspect intermediate pipe routing and identify all connection points before disassembly

Procedure

1. 1

   Remove oxygen sensor from intermediate pipe
   Disconnect oxygen sensor electrical connector by pressing release tab. Using oxygen sensor socket, carefully turn sensor counterclockwise to remove from intermediate pipe bung. If sensor is seized, apply heat carefully with propane torch to expand fitting (avoid heating sensor itself). Inspect sensor threads for damage.
2. 2

   Remove rear exhaust flange connection
   Locate the rear flange connection between intermediate pipe and rear exhaust section. Using 15mm socket, remove the flange bolts securing the connection. Note orientation of any alignment tabs. Separate flange connection and remove old gasket. If connection is seized, use pry bar carefully to separate flanges.
   ⚠Support rear exhaust section to prevent dropping when flange is separated
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
3. 3

   Disconnect exhaust hangers
   Locate the rubber exhaust hanger insulators supporting the intermediate pipe (typically 2 hangers). Using exhaust hanger tool or pry bar, carefully work each hanger rod out of the rubber insulator. If insulators are cracked or deteriorated, mark for replacement. Support pipe weight as hangers are released.
4. 4

   Remove forward exhaust flange connection
   Locate forward flange connection between intermediate pipe and catalytic converter or turbocharger downpipe. Using 15mm socket, remove exhaust flange bolts. Keep bolts organized as they may differ from rear connection. Separate flange and remove old gasket material.
   ⚠Intermediate pipe may have shifted weight - support pipe to prevent sudden dropping
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
5. 5

   Remove intermediate pipe from vehicle
   With all connections released, carefully maneuver intermediate pipe down and out from under vehicle. Pipe may need to rotate or angle to clear frame components and suspension. Inspect removed pipe for cracks, internal restrictions, or excessive corrosion.
6. 6

   Clean and prepare flange surfaces
   Using wire brush, thoroughly clean both forward and rear flange mating surfaces on remaining exhaust components. Remove all old gasket material, carbon buildup, and rust. Ensure surfaces are flat and smooth. Inspect flange surfaces for warping or damage. Clean oxygen sensor bung threads with wire brush.
7. 7

   Install oxygen sensor in new intermediate pipe
   Apply thin coat of anti-seize compound to oxygen sensor threads only (avoid contaminating sensor tip). Thread sensor by hand into new intermediate pipe bung until seated. Using oxygen sensor socket and torque wrench, tighten to specification. Verify sensor is fully seated and connector faces accessible direction.
   ⚠Do not apply anti-seize to sensor tip or contaminate sensing element
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
8. 8

   Position new intermediate pipe
   Carefully maneuver new intermediate pipe into position under vehicle, aligning forward flange first. Support pipe weight to maintain alignment. Verify oxygen sensor connector routing will not contact hot components or moving parts. Ensure pipe has adequate clearance from frame, driveshaft, and suspension components.
9. 9

   Install forward flange connection
   Position new gasket on forward flange. Align intermediate pipe flange to catalytic converter or downpipe flange. Apply anti-seize compound to exhaust flange bolt threads. Start all bolts by hand, ensuring proper thread engagement. Tighten bolts in cross-pattern to torque specification using torque wrench.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
10. 10

    Connect exhaust hangers
    Align intermediate pipe hanger rods with rubber insulator locations. Using lubricant or soapy water on insulators, work each hanger rod into rubber insulator. If replacing insulators, install new ones now. Ensure hangers are fully seated and pipe hangs naturally without binding or tension.
11. 11

    Install rear flange connection
    With hangers supporting pipe weight, position new gasket on rear flange. Align intermediate pipe rear flange to rear exhaust section flange. Start all flange bolts by hand, checking alignment tabs if equipped. Tighten bolts in cross-pattern to torque specification using torque wrench.
    Torque spec

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

    Connect oxygen sensor electrical connector
    Route oxygen sensor wiring to avoid contact with hot exhaust components. Connect electrical connector to oxygen sensor, ensuring positive click engagement. Secure any wiring clips to maintain proper routing. Verify connector lock is fully engaged.

Reassembly

1. Perform final inspection of all flange connections to verify proper torque
2. Check exhaust hanger alignment and verify pipe has adequate clearance throughout its length
3. Verify oxygen sensor wiring is routed away from heat and moving components
4. Lower vehicle from jack stands carefully

Verification

• Start engine and listen for exhaust leaks at both flange connections (hissing or ticking sounds indicate leak)
• Perform visual inspection under running vehicle for any exhaust smoke escaping from connections
• Allow engine to reach operating temperature and re-check for leaks
• Check that oxygen sensor is reporting data (scan tool check if available - should show voltage fluctuation)
• Test drive vehicle and verify no abnormal exhaust noises or rattles
• After test drive, re-inspect all connections while exhaust is hot for any seepage or discoloration indicating leaks

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