This procedure covers the removal and replacement of the exhaust resonator on a 2014 Ram 2500 with 6.7L Cummins diesel engine.

Warnings

Tools required

Parts

• Exhaust resonator assembly × 1 — Use OEM specification
• Exhaust clamps (if reusing is not possible) × 2 — Use OEM specification
• Exhaust flange gasket × 1 — Use OEM specification

Preparation

1. Ensure exhaust system has cooled completely for at least 2 hours after last operation
2. Raise vehicle on lift or safely support on jack stands at all four corners with wheels chocked
3. Spray all exhaust clamps, flange bolts, and hanger bolts with penetrating oil and allow to soak for 15-20 minutes
4. Locate the resonator assembly positioned between the DPF outlet and muffler assembly, approximately mid-vehicle

Procedure

1. 1

   Disconnect upstream exhaust connection
   Locate the band clamp or flange connection between the diesel particulate filter (DPF) outlet pipe and the resonator inlet. If equipped with a band clamp, loosen the clamp bolt completely but do not remove. If equipped with a flange connection, remove the two flange bolts securing the joint. Separate the connection carefully, noting the position of any gaskets.
   Torque spec

   Exhaust Clamps55 Nm (41 lb-ft)

   Flange Bolts45 Nm (33 lb-ft)
2. 2

   Disconnect downstream exhaust connection
   Locate the band clamp or flange connection between the resonator outlet and the muffler inlet pipe. Loosen the clamp bolt completely or remove flange bolts as equipped. Gently separate the connection, taking care not to damage the muffler inlet pipe.
   Torque spec

   Exhaust Clamps55 Nm (41 lb-ft)

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

   Remove exhaust hanger supports
   Identify the rubber exhaust hangers supporting the resonator assembly. Typically there are two hanger points on this section. Use a pry bar or exhaust hanger tool to carefully slide the rubber isolators off the metal hanger pins. Support the resonator weight as you remove the hangers to prevent it from falling.
   Torque spec

   Hanger Bolts27 Nm (20 lb-ft)
4. 4

   Remove resonator assembly
   With all connections and hangers released, carefully lower and remove the resonator assembly from the vehicle. The assembly may still contain soot residue. Maneuver it around the driveshaft and 4WD components as necessary to extract it from underneath the vehicle.
5. 5

   Clean mating surfaces
   Use a wire brush to thoroughly clean the exhaust pipe ends at both the upstream (DPF outlet) and downstream (muffler inlet) connections. Remove all carbon buildup, old gasket material, and corrosion. If equipped with flange connections, ensure mating surfaces are flat and free of debris. Inspect pipes for cracks or damage.
6. 6

   Prepare new resonator
   Unpack the new resonator assembly and verify it matches the original configuration including inlet/outlet diameter and overall length. Check that mounting brackets and hanger provisions are in the correct positions. Apply a thin coat of anti-seize compound to clamp bolt threads or flange bolt threads.
7. 7

   Position new resonator
   Carefully maneuver the new resonator into position underneath the vehicle, routing it around driveshaft and 4WD components. Align the inlet end with the DPF outlet pipe and outlet end with the muffler inlet pipe. Support the resonator at the correct height to allow hanger installation.
8. 8

   Install exhaust hangers
   Attach the rubber exhaust isolators to the hanger pins on the resonator mounting brackets. Ensure the rubber isolators are fully seated on the pins and that the resonator is properly supported and aligned with adjacent exhaust components. Adjust position as needed for proper alignment.
   Torque spec

   Hanger Bolts27 Nm (20 lb-ft)
9. 9

   Connect upstream exhaust joint
   Align the resonator inlet with the DPF outlet pipe. If equipped with a flange connection, install new gasket and thread in flange bolts. Hand tighten bolts in a cross pattern, then torque to specification. If equipped with band clamp, position clamp over joint with clamp bolt accessible and tighten to specification.
   Torque spec

   Flange Bolts45 Nm (33 lb-ft)

   Exhaust Clamps55 Nm (41 lb-ft)
10. 10

    Connect downstream exhaust joint
    Align the resonator outlet with the muffler inlet pipe. Install new gasket if flange-type connection, then install and hand tighten fasteners. For band clamp connections, position clamp and tighten bolt. Torque all fasteners to specification using a cross pattern for flange bolts.
    Torque spec

    Flange Bolts45 Nm (33 lb-ft)

    Exhaust Clamps55 Nm (41 lb-ft)
11. 11

    Verify alignment and clearances
    Inspect the entire exhaust system from DPF to muffler outlet. Ensure there is adequate clearance between exhaust components and the driveshaft, frame rails, fuel tank, and heat shields. Verify no exhaust components are contacting the body or chassis. Adjust hanger positions if necessary to achieve proper clearance (minimum 1/2 inch from all components).

Reassembly

1. Double-check all clamp and flange connections are torqued to specification
2. Ensure all rubber exhaust hangers are properly seated and not twisted
3. Verify adequate clearance exists between all exhaust components and vehicle underbody

Verification

• Lower vehicle and start engine, allowing it to idle
• Listen for exhaust leaks at both resonator connections - a hissing or ticking sound indicates a leak
• Perform a visual inspection underneath the vehicle while engine is running to check for visible exhaust leaks
• With engine at operating temperature, verify no exhaust components are contacting the chassis or body
• Test drive vehicle and listen for any rattles or abnormal exhaust noise, particularly during acceleration
• After test drive, re-inspect all connections for signs of leakage or loosening

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