Exhaust Hangers

This procedure covers the inspection and replacement of exhaust system hangers on a 2007 Ram 3500 with 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Exhaust hanger insulators × 4 — Use OEM specification

Preparation

1. Park vehicle on level ground and apply parking brake
2. Place wheel chocks at front wheels
3. Allow exhaust system to cool completely (minimum 2 hours after running)
4. Raise rear of vehicle using floor jack and support on jack stands rated for vehicle weight
5. Spray all exhaust hanger mounting points with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Locate exhaust hangers
   Inspect the exhaust system from underneath the vehicle. On the 2007 Ram 3500 with 5.9L Cummins, inspect the entire exhaust system to determine the exact number of rubber hanger insulators, as counts vary by cab/bed configuration. Identify all hanger locations before ordering parts. Identify all hanger locations from the turbo outlet pipe rearward to the tailpipe. Note which hangers are cracked, torn, or deteriorated.
2. 2

   Inspect hanger condition
   Examine each rubber insulator for cracks, tears, deterioration, or separation from the metal hangers. Check frame-mounted brackets for rust or damage. The insulators should be pliable and show no signs of cracking. Replace any that show wear or damage.
3. 3

   Remove first hanger insulator
   Starting at the front of the exhaust system, use a flat pry bar to carefully lever the exhaust pipe hanger stud out of the rubber insulator. Insert the pry bar between the exhaust pipe and frame bracket, applying upward or downward pressure as needed to relieve tension on the insulator. Work the metal stud out of the rubber grommet by prying gently. If severely deteriorated, the rubber may need to be cut away.
4. 4

   Remove remaining hangers
   Work from front to rear, removing each subsequent hanger insulator using the same prying technique. Support the exhaust pipe with one hand or have an assistant support it to prevent excessive movement that could stress remaining hangers or damage exhaust components. The exhaust system will drop slightly as hangers are removed.
5. 5

   Clean hanger mounting points
   Use a wire brush to clean rust and debris from the frame-mounted hanger brackets and the metal studs on the exhaust pipes. Remove any remnants of old rubber from the mounting points. This ensures proper seating of new insulators.
6. 6

   Install new hanger insulators on brackets
   Install new rubber hanger insulators onto the frame-mounted brackets first. Push the bracket hook through the center hole of the rubber insulator. Apply spray lubricant to the inside of the insulator hole to ease installation if needed. Ensure the insulator is fully seated on the bracket.
7. 7

   Position exhaust into hangers
   With new insulators mounted on the frame brackets, lift the exhaust pipe to align the metal studs with the holes in the rubber insulators. You may need to apply upward or sideways pressure on the exhaust pipe to align properly. Work from front to rear, inserting each exhaust hanger stud into its corresponding rubber insulator.
8. 8

   Seat hangers fully
   Use the pry bar to help lever the exhaust pipe studs fully into the rubber insulators. The metal stud should be centered in the rubber grommet with equal amounts of rubber visible on all sides. Ensure each hanger is fully engaged and the exhaust system is properly supported at all points.
9. 9

   Check exhaust alignment and clearance
   Verify the exhaust system has proper clearance from the frame, fuel tank, brake lines, and body components. There should be at least 1 inch of clearance at all points. Check that the tailpipe exits straight and is not cocked to one side. Adjust by repositioning hangers if necessary.

Reassembly

1. Double-check that all hanger insulators are fully seated and supporting the exhaust system
2. Verify no exhaust components are contacting the frame, body, or drivetrain
3. Remove jack stands and carefully lower vehicle to ground

Verification

• Start the engine and listen for any new rattles or contact points between exhaust and vehicle
• With engine running, have an assistant observe the exhaust system for excessive movement or vibration
• Visually inspect from underneath while engine is running to confirm all hangers are holding properly and exhaust is not sagging
• Take a short test drive and listen for any abnormal exhaust noise or vibration that would indicate improper hanger installation

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