This procedure covers the removal and replacement of the muffler on a 2014 Ram 2500 with the 6.7L Cummins Diesel engine, including disconnecting exhaust clamps, hangers, and properly torquing all fasteners during reinstallation.

Warnings

Tools required

Parts

• Muffler assembly × 1 — Use OEM specification or aftermarket equivalent for 6.7L Cummins
• Exhaust gaskets (if equipped at muffler inlet) × 1 — Use OEM specification
• Exhaust clamps (if corroded) × 2 — Use OEM specification
• Rubber exhaust hangers (if deteriorated) × 3 — Use OEM specification

Preparation

1. Ensure the exhaust system is completely cool to the touch
2. Raise vehicle on a lift or securely support on jack stands rated for the vehicle weight
3. Apply penetrating oil to all muffler clamp bolts, flange bolts, and hanger fasteners
4. Inspect the entire exhaust system for rust, corrosion, or damage that may complicate removal
5. Position an exhaust support jack or have an assistant ready to support the muffler weight during removal

Procedure

1. 1

   Locate and inspect muffler assembly
   From under the vehicle, locate the muffler assembly positioned mid-chassis. On the 2014 Ram 2500 with 6.7L Cummins, the muffler is located behind the transmission crossmember and ahead of the tailpipe. Identify the inlet connection (from the DPF system), outlet connection (to tailpipe), and all rubber hanger mounting points (typically 2-3 hangers).
2. 2

   Support muffler assembly
   Position an exhaust support jack or have an assistant support the weight of the muffler from below. The muffler assembly weighs approximately 30-40 lbs and will drop when hangers are released. Ensure adequate support to prevent damage to surrounding components or injury.
3. 3

   Disconnect inlet connection
   Locate the muffler inlet connection to the DPF outlet pipe. This may be a bolted flange connection or a band clamp. If flange-bolted, remove the bolts using a 15mm socket. If band-clamped, loosen the clamp bolt using a 13mm or 15mm socket (depending on clamp type). Separate the joint carefully and inspect the gasket condition.
4. 4

   Disconnect outlet connection
   Move to the muffler outlet where it connects to the tailpipe. This is typically a slip-fit connection secured with a band clamp. Loosen the muffler clamp bolt using a 15mm socket. Once loose, attempt to separate the connection. If seized, apply additional penetrating oil and gently twist the pipes while pulling apart.
   Torque spec

   Muffler Clamps55 Nm (41 lb-ft)
5. 5

   Release exhaust hangers
   Locate all rubber exhaust hangers supporting the muffler (typically 2-3 mounting points). Using a pry bar or exhaust hanger removal tool, pry the rubber hanger bushings off the metal hanger rods. Work carefully to avoid tearing the rubber bushings if they are to be reused. If hangers are mounted with bolts to the chassis, remove hanger bracket bolts using a 13mm socket.
   Torque spec

   Hanger Bracket Bolts25 Nm (18 lb-ft)
6. 6

   Remove muffler assembly
   With all connections and hangers released, carefully lower the muffler assembly from the vehicle. Maneuver it around the frame rails, driveshaft, and other components. The muffler may need to be angled or rotated to clear obstructions. Have your assistant help control the descent to prevent it from falling.
7. 7

   Clean and inspect mounting points
   With the muffler removed, use a wire brush to clean all connection points, flange surfaces, and hanger rods. Remove rust, carbon deposits, and old gasket material from flange surfaces. Inspect hanger rods for damage or excessive rust. Check rubber hanger bushings for cracks, tears, or deterioration and replace if necessary. Inspect the inlet and outlet pipes for damage or excessive corrosion.
8. 8

   Prepare new muffler for installation
   Unpack the new muffler and verify it matches the original configuration with correct inlet/outlet diameters and hanger positions. If equipped with a flange connection at the inlet, install a new exhaust gasket. Apply anti-seize compound to all flange bolt threads and clamp bolt threads to prevent future seizure.
9. 9

   Position and install new muffler
   With assistance or using an exhaust jack, lift the new muffler into position under the vehicle. Align the inlet connection first, inserting it into or onto the DPF outlet pipe. Loosely install inlet flange bolts or clamp, but do not fully tighten yet. Then align the outlet to the tailpipe and loosely install the muffler clamp.
10. 10

    Install exhaust hangers
    With the muffler loosely connected at both ends, install the rubber hanger bushings onto the metal hanger rods. Use a pry bar or soapy water to ease installation. Ensure all hangers are fully seated. If bracket-mounted hangers are used, install and loosely tighten hanger bracket bolts. Adjust the muffler position to ensure proper clearance from the chassis, driveshaft, fuel tank, and spare tire (if equipped).
11. 11

    Align and check clearances
    Before final tightening, verify the entire exhaust system has adequate clearance from all chassis components, suspension parts, driveshaft, and fuel system components. Minimum clearance should be 1 inch from all heat-sensitive components. Ensure the muffler and tailpipe are properly aligned and not under stress or binding. Make adjustments as needed by repositioning hangers.
12. 12

    Torque inlet connection
    Beginning at the inlet, torque the flange bolts or clamp bolts to specification using a torque wrench. If using flange bolts, ensure anti-seize was applied and torque in a cross-pattern to ensure even gasket compression. This creates a proper seal and prevents exhaust leaks.
13. 13

    Torque outlet connection and hangers
    Torque the muffler outlet clamp to specification using a torque wrench. Then torque all hanger bolts and hanger bracket bolts to their specified values. Double-check all connections are secure and properly aligned after torquing.
    Torque spec

    Muffler Clamps55 Nm (41 lb-ft)

    Hanger Bracket Bolts25 Nm (18 lb-ft)
14. 14

    Final inspection
    Perform a final visual inspection of all connections, hangers, and clearances. Verify all fasteners are torqued and no tools or parts were left under the vehicle. Check that the tailpipe exit is properly positioned and clears the bumper.

Reassembly

1. Lower the vehicle from the lift or jack stands
2. Start the engine and allow it to idle for 2-3 minutes
3. Listen carefully for any exhaust leaks at the muffler connections while the engine is running
4. If leaks are detected, raise the vehicle and check torque specifications and gasket seating
5. After initial run, re-check all clamp and bolt torque values after the system has heated and cooled once

Verification

• Start the engine and verify no exhaust leaks are present at the inlet or outlet connections
• Rev the engine to 2000 RPM and listen for rattles, vibrations, or contact with chassis components
• Perform a test drive and listen for any abnormal exhaust noises or vibrations
• After test drive, re-inspect all connections and hangers for proper torque and alignment
• Verify proper exhaust flow and no decrease in engine performance
• Check that no exhaust odors are entering the cabin during operation

More procedures for this vehicle