Resonator

This procedure covers the removal and replacement of the exhaust resonator on a 2007 Ram 3500 with the 5.9L Cummins diesel engine and 4WD configuration.

Warnings

Tools required

Parts

• Exhaust resonator assembly × 1 — Use OEM specification or equivalent aftermarket
• Exhaust clamp kit (if not welded) × 1 — Typically 4-inch diameter for Cummins exhaust
• Rubber exhaust hangers × 2 — Replace if damaged or deteriorated

Preparation

1. Park vehicle on level ground and apply parking brake
2. Place wheel chocks behind rear wheels
3. Allow exhaust system to cool completely (minimum 2 hours after engine operation)
4. Raise front of vehicle with floor jack and support securely on jack stands under frame rails
5. Inspect resonator location and exhaust routing from underneath to identify connection points
6. Apply penetrating oil to all clamp bolts and hanger attachment points, allow to soak 15-20 minutes

Procedure

1. 1

   Locate and inspect resonator assembly
   Position yourself under the vehicle with adequate lighting. The resonator is located in the exhaust system downstream of the turbocharger downpipe and catalytic converter, typically mid-chassis ahead of or combined with the muffler. Identify whether the resonator is connected with band clamps or welded joints. Note the position of rubber exhaust hangers supporting the resonator.
2. 2

   Support exhaust system
   Position a jack stand or block of wood under the exhaust pipe behind the resonator to support the weight of the rear exhaust section. This prevents stress on downstream components when the resonator is disconnected.
3. 3

   Remove front exhaust clamp
   Using the appropriate size socket (commonly 13mm or 15mm) and extension, loosen and remove the nuts from the band clamp connecting the resonator inlet to the upstream exhaust pipe. If clamp is severely corroded, apply additional penetrating oil and use a wire brush to clean threads. Once nuts are removed, spread clamp slightly and slide it forward on the pipe away from the joint.
4. 4

   Remove rear exhaust clamp
   Using the appropriate size socket (commonly 13mm or 15mm) and extension, loosen and remove the nuts from the band clamp connecting the resonator outlet to the downstream exhaust pipe or muffler. Spread clamp and slide it rearward away from the joint. If the system is welded, mark the cut location approximately 2 inches from each end of the resonator and use a reciprocating saw or exhaust pipe cutter to make clean cuts.
5. 5

   Disconnect exhaust hangers
   Locate the rubber exhaust hangers supporting the resonator (typically 1-2 hangers). Use an exhaust hanger removal tool or pry bar to carefully separate the metal hanger loop from the rubber isolator. Work the hanger side to side while applying gentle pulling force. Inspect rubber isolators for cracking or deterioration and replace if necessary.
6. 6

   Remove resonator assembly
   With all clamps and hangers disconnected, carefully separate the resonator from the exhaust pipes. You may need to twist and pull the resonator to break it free from pipe connections. Lower the resonator down and remove it from under the vehicle. Be aware that residual soot and condensation may drain from the pipes.
7. 7

   Clean and prepare exhaust pipes
   Use a wire brush to clean the ends of both the upstream and downstream exhaust pipes where they will connect to the new resonator. Remove all carbon buildup, rust, and debris to ensure proper sealing. Inspect pipe ends for damage, excessive corrosion, or deformation that may prevent proper clamping.
8. 8

   Install new resonator
   Position the new resonator under the vehicle, aligning it with the exhaust pipe connections. Ensure the resonator is oriented correctly with the inlet facing forward toward the upstream exhaust pipe (from the catalytic converter and turbocharger). Slide the inlet end onto the upstream exhaust pipe first, inserting approximately 2-3 inches of overlap.
9. 9

   Connect exhaust hangers
   Attach the resonator's hanger loops to the rubber isolators mounted on the vehicle frame or crossmember. You may need to adjust the resonator position slightly to align the hangers. Use a pry bar if necessary to stretch the rubber isolators over the metal loops. Ensure hangers are fully seated.
10. 10

    Align and connect rear exhaust section
    With the resonator supported by its hangers, align the outlet end with the downstream exhaust pipe or muffler inlet. Slide the pipes together with 2-3 inches of overlap. Adjust the entire assembly to ensure adequate clearance from the chassis, driveshaft, fuel tank, and suspension components (minimum 1 inch from most components, and greater clearance plus factory heat shields retained near the fuel tank and other heat-sensitive parts).
11. 11

    Install and tighten exhaust clamps
    Slide the front band clamp into position over the inlet joint, centering it on the overlapping pipe section. Install the clamp nuts and tighten evenly in a criss-cross pattern using a 15mm socket. Tighten firmly but do not overtighten, as this can deform the pipes. Repeat for the rear clamp at the outlet joint. Ensure clamps are positioned with nuts accessible for future service.
12. 12

    Final inspection and clearance check
    Remove the temporary support from under the rear exhaust section. Visually inspect all connections to ensure clamps are properly seated and hangers are secure. Check exhaust system clearance by grasping pipes and moving them gently to verify no contact with chassis, driveshaft, or suspension at any point in the travel range. Verify at least 1 inch of clearance at all points.

Reassembly

1. Ensure all exhaust clamps are tightened securely and positioned correctly over pipe joints
2. Verify all rubber exhaust hangers are properly engaged and not twisted or stressed
3. Double-check clearances around entire exhaust system before lowering vehicle
4. Remove jack stands and lower vehicle to ground

Verification

• Start engine and allow to idle. Listen for exhaust leaks at resonator connections (hissing or ticking sounds indicate leak)
• Perform visual inspection under running vehicle for any visible exhaust escaping from joints
• With engine at idle, feel around clamp connections (without touching hot components) to detect escaping exhaust gases
• Take vehicle for short test drive and re-check all clamp tightness after exhaust system has heated and cooled through one cycle
• Re-inspect exhaust clearances after test drive to ensure nothing has shifted during thermal expansion

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