Exhaust Tip

This procedure covers the removal and installation of the exhaust tip on a 2007 Ram 3500 with the 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Exhaust tip × 1 — Aftermarket or OEM replacement tip with appropriate inlet diameter
• Exhaust clamp (if required) × 1 — Match to exhaust pipe diameter, typically 4-5 inch

Preparation

1. Ensure engine and exhaust system are completely cold to the touch
2. Park vehicle on level ground and set parking brake
3. If additional clearance is needed, raise and support the rear of the vehicle on jack stands at the frame rails
4. Locate the exhaust tip at the rear of the vehicle - it may be clamped or welded to the tailpipe
5. Apply penetrating oil liberally to any clamp bolts or fasteners and allow 15-20 minutes to soak

Procedure

1. 1

   Inspect tip attachment method
   Examine how the exhaust tip is attached to the tailpipe. Most aftermarket tips use a band clamp that wraps around the tailpipe. Factory tips may be welded or use a different clamp style. Identify the fastener type (typically one or two nuts/bolts on a band clamp).
2. 2

   Remove clamp fasteners
   Using the appropriate socket, loosen and remove the nuts or bolts securing the exhaust clamp. If the tip is clamped, there will typically be one bolt on a worm-drive style clamp or two nuts on a band clamp. Work slowly and apply additional penetrating oil if fasteners are seized. If fasteners break, the clamp can be cut off with a grinder or replaced.
3. 3

   Loosen and remove clamp
   Once fasteners are removed, spread the clamp open using large pliers or an exhaust clamp tool. On worm-drive clamps, the clamp may simply slide off once loosened. On band clamps, you may need to work the clamp around the pipe to remove it completely. Set the old clamp aside if it will be reused.
4. 4

   Remove old exhaust tip
   Grasp the exhaust tip firmly and twist while pulling rearward to break it free from the tailpipe. The tip may be stuck due to carbon buildup and corrosion. If stuck, apply more penetrating oil at the junction and allow to soak, then twist and pull with increased force. Avoid excessive bending of the tailpipe.
5. 5

   Clean tailpipe end
   Use a wire brush to clean the outside diameter of the tailpipe where the new tip will slide on. Remove all rust, carbon deposits, and old exhaust sealant. The surface should be reasonably smooth to allow proper fit of the new tip and prevent exhaust leaks. Wipe clean with a shop towel.
6. 6

   Test fit new exhaust tip
   Slide the new exhaust tip onto the tailpipe to verify proper fit. The tip should slide on with moderate resistance and cover an appropriate length of the tailpipe (typically 1-3 inches depending on the tip design). Ensure the tip is oriented correctly with any logos or design features in the desired position. Mark the tailpipe at the desired depth if needed.
7. 7

   Apply anti-seize and install tip
   Remove the tip and apply a thin coat of high-temperature anti-seize compound to the outside of the tailpipe where the tip will mount. This will prevent future seizing and make removal easier. Slide the tip onto the tailpipe to the previously determined depth, rotating to the desired orientation.
8. 8

   Install and position clamp
   Place the exhaust clamp (new or reused) around the tip at the junction where it meets the tailpipe. Position the clamp so the fasteners are accessible from below or the side. Ensure the clamp is centered over the joint for maximum sealing effectiveness.
9. 9

   Tighten clamp securely
   Hand-start the clamp fasteners, then tighten gradually and evenly. On band clamps with two nuts, alternate between them to ensure even pressure. Tighten firmly until the clamp compresses and the tip cannot be rotated by hand. Do not overtighten to the point of deforming the tailpipe or tip. Verify the tip orientation is still correct.

Reassembly

1. If the vehicle was raised, lower it from jack stands and remove stands before starting the engine
2. Double-check that the exhaust tip is secure and properly oriented before final verification

Verification

• Start the engine and allow it to idle
• Walk to the rear of the vehicle and inspect for exhaust leaks at the tip/tailpipe junction - look for visible smoke or listen for hissing sounds
• With the engine running, feel around the clamp area (without touching hot components) for escaping exhaust gases
• Verify the tip remains secure and does not rattle or vibrate excessively
• Rev the engine slightly to increase exhaust flow and recheck for leaks
• If any leaks are detected, shut off the engine, allow to cool, and retighten the clamp or reposition the tip as needed

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