Exhaust Pipe - Rear Section

This procedure covers removal and replacement of the rear exhaust pipe section on a 2007 Ram 3500 with 5.9L Cummins diesel engine, from the muffler to the tailpipe outlet.

Warnings

Tools required

Parts

• Rear exhaust pipe section × 1 — OEM or aftermarket equivalent for 2007 Ram 3500 5.9L Cummins
• Exhaust clamp (muffler to tailpipe) × 1 — 3.5 inch band clamp
• Exhaust hangers (rubber isolators) × 2 — Replace if cracked or deteriorated
• Exhaust gasket × 1 — Use OEM specification if flange connection present

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks in front of front wheels
3. Allow exhaust system to cool completely (minimum 1 hour after engine operation)
4. Raise rear of vehicle with floor jack and support securely on jack stands rated for vehicle weight
5. Spray all exhaust clamps, bolts, and hanger points with penetrating oil and allow to soak for 15-20 minutes

Procedure

1. 1

   Inspect exhaust routing and connections
   Visually inspect the rear exhaust section from underneath the vehicle. Identify the connection point at the muffler outlet, all rubber hanger locations (typically 2-3 hangers), and the tailpipe exit point. Note the position of any heat shields or exhaust tip orientation for proper reinstallation.
2. 2

   Disconnect oxygen sensor if equipped
   This 5.9L Cummins diesel does not use oxygen sensors like a gasoline engine. The rear exhaust section on this diesel typically has no exhaust sensors. Verify there are no sensors or wiring harnesses attached to the rear pipe section before removal; if any emissions-related sensor is present, disconnect its electrical connector and remove it carefully for reuse.
   ⚠Oxygen sensors are fragile and expensive. Do not allow the sensor to hang by its wiring.
3. 3

   Loosen muffler-to-tailpipe connection
   Locate the band clamp or bolted flange connecting the muffler outlet to the rear pipe section. If using a band clamp, loosen the clamp bolt completely (verify the correct wrench size, commonly 15mm or 1/2 inch) but do not remove the clamp yet. If a bolted flange is present, loosen all bolts evenly using a 13mm wrench. Apply additional penetrating oil if fasteners are seized.
   ⚠Band clamp bolts may snap if corroded. Use a backup wrench on the clamp nut to prevent twisting the entire clamp.
4. 4

   Support the rear pipe section
   Position a floor jack or have a helper support the weight of the rear exhaust section to prevent it from falling when hangers are disconnected. The pipe assembly can be heavy and awkward to handle.
5. 5

   Remove exhaust from rubber hangers
   Using a pry bar or exhaust hanger removal tool, carefully lever the exhaust pipe mounting tabs out of the rubber hanger isolators. Start with the rearmost hanger and work forward. Apply penetrating oil to stubborn hangers. Twist and pull the pipe tab while prying to release from the rubber grommet.
   ℹ️Rubber hangers may tear during removal if old or brittle. Inspect all hangers and replace as needed.
6. 6

   Separate pipe from muffler connection
   With the pipe supported and hangers disconnected, fully separate the rear pipe section from the muffler outlet. If using a band clamp connection, slide the pipe rearward to clear the joint. For flanged connections, carefully wiggle the pipe free while pulling rearward. Remove the old gasket material from the muffler outlet if applicable.
7. 7

   Remove rear exhaust section from vehicle
   Carefully lower and maneuver the rear pipe section out from under the vehicle. Watch for interference with the rear axle, spare tire, or frame components. The pipe may need to be angled or rotated during removal.
8. 8

   Clean mating surfaces
   Using a wire brush, thoroughly clean the muffler outlet pipe where the new section will connect. Remove all rust, old gasket material, and carbon buildup. Clean the exhaust hanger mounting points on the frame to ensure proper rubber isolator seating.
9. 9

   Prepare new rear pipe section
   Unpack the new rear exhaust pipe section and verify it matches the original configuration. This diesel does not use an oxygen sensor, so no sensor reinstallation is required in the rear pipe section. If any emissions sensor was removed, reinstall it and torque according to the manufacturer specification. Install new rubber hanger isolators onto frame mounting brackets if replacing.
10. 10

    Position new pipe section
    Maneuver the new rear pipe section into position under the vehicle, routing it along the same path as the original. Align the inlet end with the muffler outlet connection. Have a helper support the pipe or use a floor jack to hold it in position.
11. 11

    Install exhaust hangers
    Insert each exhaust pipe mounting tab into its corresponding rubber hanger isolator. Start with the forward hanger and work rearward. Use a pry bar or soapy water to ease installation. Ensure tabs are fully seated in the rubber grommets.
12. 12

    Connect pipe to muffler
    Slide the new pipe section onto the muffler outlet (or align flange if applicable). Install a new band clamp over the joint or position a new gasket between flanges. Hand-tighten the band clamp bolt or flange bolts to hold the connection loosely.
13. 13

    Align exhaust system
    Check the entire rear pipe section for proper alignment and clearance. Verify the tailpipe exit is positioned correctly and all pipe sections have adequate clearance from the frame, axle, spare tire, and body components (minimum 1 inch clearance recommended). Adjust as needed by rotating pipes at the slip joint or repositioning on hangers.
14. 14

    Tighten all connections
    Once alignment is verified, fully tighten the muffler connection. For band clamps, tighten the clamp bolt (verify correct wrench size, commonly 15mm or 1/2 inch) until the clamp is snug and seals the joint; consult the clamp manufacturer's torque specification rather than relying on a generic value. For flanged connections, tighten bolts in a cross-pattern to ensure even gasket compression. Do not overtighten as this can crack flanges.
15. 15

    Reconnect oxygen sensor wiring
    If any emissions sensor was disconnected, reconnect the electrical connector ensuring it clicks securely. Route the wiring away from hot exhaust surfaces and ensure it has slack for movement without tension.

Reassembly

1. Double-check all connections are tight and properly aligned before lowering vehicle
2. Verify all rubber hangers are properly seated and supporting the exhaust weight evenly
3. Confirm oxygen sensor wiring is connected and properly routed if applicable

Verification

• Lower vehicle from jack stands carefully
• Start engine and listen for exhaust leaks at the muffler connection (ticking or hissing sounds indicate a leak)
• With engine running, visually inspect the new rear pipe section for smoke or visible exhaust leaks
• Check for proper exhaust tip position and verify no contact with body panels or bumper
• Rev engine slightly and verify exhaust system does not contact frame, axle, or body components during movement
• Take a short test drive and recheck all connections and clearances after the exhaust system has heated and cooled through one cycle

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