Intermediate Pipe

Replace the exhaust intermediate pipe section on a 2007 Ram 3500 with 5.9L Cummins diesel engine, connecting the turbocharger downpipe to the muffler assembly.

Warnings

Tools required

Parts

• Intermediate exhaust pipe × 1 — Use OEM specification or aftermarket equivalent for 2007 Ram 3500 5.9L Cummins
• Exhaust flange gasket (downpipe to intermediate pipe) × 1 — 3-bolt flange gasket
• Exhaust flange gasket (intermediate pipe to muffler) × 1 — Use OEM specification
• Exhaust clamp hardware × 1 — If equipped with band clamps
• Exhaust flange bolts/nuts × 6 — M10 or M12 depending on connection type

Preparation

1. Park vehicle on level surface and apply parking brake. Place wheel chocks behind rear wheels.
2. Allow exhaust system to cool completely (at least 2 hours after engine operation).
3. Raise vehicle with floor jack at frame rails and support securely on jack stands rated for vehicle weight. Ensure adequate working clearance underneath.
4. Spray all exhaust flange bolts, nuts, and clamps with penetrating oil. Allow to soak for at least 15-30 minutes before beginning removal.
5. Inspect the intermediate pipe location and trace connections from turbocharger downpipe to muffler inlet to identify all attachment points.
6. Check for exhaust hangers supporting the intermediate pipe and note their locations.

Procedure

1. 1

   Remove downpipe to intermediate pipe connection
   Locate the flange connection between the turbocharger downpipe and the intermediate pipe (typically a 3-bolt flange). Using the appropriate socket (verify size against the actual hardware, commonly 13mm-15mm), remove the three bolts or nuts securing this connection. If fasteners are seized, apply additional penetrating oil and use a breaker bar for additional leverage. Support the intermediate pipe weight with an exhaust jack or adjustable stand as you loosen the last fastener.
2. 2

   Separate downpipe flange connection
   Once fasteners are removed, use a pry bar or exhaust separator tool to carefully break the connection between the downpipe and intermediate pipe flanges. The old gasket may be stuck. Work the pipe back and forth gently to separate. Do not damage the downpipe flange surface.
3. 3

   Remove intermediate pipe to muffler connection
   Move to the rear connection where the intermediate pipe meets the muffler inlet. This may be a bolted flange or a band clamp connection; verify the fastener size against the actual hardware before selecting a socket. Remove the fasteners completely. If a band clamp is used, loosen the clamp bolt and remove the clamp from around the joint.
4. 4

   Disconnect exhaust hangers
   Locate all rubber exhaust hangers supporting the intermediate pipe section. Using a pry bar or by hand, carefully work the metal hooks out of the rubber isolators. Spray with soapy water if needed to ease removal. Note the orientation of hangers for reassembly.
5. 5

   Remove intermediate pipe
   With all connections and hangers disconnected, carefully lower and remove the intermediate pipe from the vehicle. The pipe may be heavy and awkward to maneuver around the chassis and drivetrain components. Work slowly and avoid damaging brake lines, fuel lines, or wiring.
6. 6

   Clean flange surfaces
   Using a wire brush and scraper, thoroughly clean the flange surfaces on both the downpipe and muffler inlet. Remove all old gasket material, carbon buildup, and rust. Clean surfaces ensure proper sealing with new gaskets. Inspect flanges for cracks or warping.
7. 7

   Install new gaskets
   Position new exhaust gaskets on the downpipe flange and muffler inlet flange. Ensure gaskets are properly aligned with bolt holes. Some gaskets have directional markings or specific orientations.
8. 8

   Position new intermediate pipe
   Lift the new intermediate pipe into position, aligning it first with the downpipe flange connection. Support the pipe weight with an exhaust jack or have an assistant hold it in position. Ensure the pipe routing matches the original and clears all chassis components, brake lines, and fuel lines.
9. 9

   Install downpipe connection hardware
   Insert the bolts or studs through the downpipe flange connection and start the nuts by hand. Do not fully tighten yet. Thread all fasteners enough to hold the connection together but allow for adjustment. Torque specifications for these exhaust flange connections must be verified in the factory service manual for the 2007 Ram 3500 5.9L Cummins, as no verified specific values are available in the database.
10. 10

    Install muffler connection hardware
    Move to the rear connection and align the intermediate pipe with the muffler inlet. Install the flange bolts or band clamp hardware. Start all fasteners by hand but do not fully tighten. Ensure proper alignment of the entire exhaust system before final tightening.
11. 11

    Reconnect exhaust hangers
    Work the metal hanger hooks back into the rubber isolators at all support points. Use soapy water as lubricant if needed. Ensure hangers are fully seated and supporting the pipe properly. The exhaust system should hang naturally without stress or binding.
12. 12

    Align and adjust exhaust system
    With all connections loose, adjust the intermediate pipe position to ensure proper clearance from chassis components, driveshaft, and frame rails. There should be at least 1 inch of clearance all around. Check that the pipe is not twisted or under stress. Adjust hanger positions if needed.
13. 13

    Torque all connections
    Once alignment is verified, torque all flange bolts in a crisscross pattern to ensure even clamping pressure. Use a torque wrench set to the manufacturer specifications from the factory service manual for the 2007 Ram 3500 5.9L Cummins. If band clamps are used, tighten to the clamp manufacturer's specified torque. Recheck all fasteners after initial tightening.

Reassembly

1. Double-check all exhaust connections are tight and properly torqued.
2. Verify exhaust hangers are fully seated in rubber isolators and supporting the system.
3. Confirm adequate clearance between exhaust pipe and all chassis components, fuel lines, brake lines, and driveshaft.
4. Lower vehicle from jack stands carefully and remove jack stands.

Verification

• Start the engine and listen for exhaust leaks at the flange connections. A hissing sound indicates a leak that requires retightening or gasket inspection.
• With the engine running, visually inspect all connections for escaping exhaust gases.
• Allow engine to reach operating temperature and recheck for leaks under load.
• Check exhaust pipe clearance while an assistant turns the steering wheel lock to lock to ensure no interference with moving components.
• Take a short test drive and listen for rattles, buzzing, or exhaust contact with the vehicle body. Recheck all fasteners after test drive.
• After 50-100 miles of driving, recheck and retorque all exhaust flange connections as they may settle after heat cycling.

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