Tail Pipe

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

Warnings

Tools required

Parts

• Tailpipe assembly × 1 — Use OEM specification for 5.9L Cummins diesel
• Exhaust clamp × 1 — 3.5 inch band clamp
• Rubber exhaust hangers × 2 — Replace if damaged

Preparation

1. Ensure exhaust system is completely cool to the touch
2. Park vehicle on level ground and set parking brake
3. Place wheel chocks at front wheels
4. Raise vehicle on lift or with floor jack and support securely on jack stands at frame rails
5. Spray all exhaust clamp bolts and hanger connections with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Access tailpipe assembly
   Position yourself under the rear of the vehicle with adequate lighting. Locate the tailpipe which runs from the muffler outlet rearward and exits on the passenger side of the vehicle. Verify the exact exit routing on your specific truck, as configurations vary. Identify the band clamp connecting the tailpipe to the muffler and the two rubber hangers supporting the tailpipe.
2. 2

   Remove exhaust clamp
   Using the appropriate socket and ratchet (commonly 13mm or 15mm), loosen and remove the nut and bolt securing the band clamp that connects the tailpipe to the muffler outlet. The clamp may be corroded; apply additional penetrating oil if necessary. Once the bolt is removed, work the clamp off the joint and set aside.
3. 3

   Disconnect front hanger
   Locate the front rubber exhaust hanger that supports the tailpipe near the muffler connection point. Using an exhaust hanger removal tool or pry bar, carefully work the hanger grommet off the support bracket stud. Apply steady pressure to avoid tearing the rubber if you plan to reuse it.
4. 4

   Disconnect rear hanger
   Move to the rear exhaust hanger located near the tailpipe exit point. Using the same technique, carefully pry the rubber hanger grommet off the support bracket stud. The tailpipe should now be free from all mounting points.
5. 5

   Remove tailpipe
   With all connections released, slide the tailpipe rearward to disengage it from the muffler outlet pipe. You may need to twist and rotate the pipe slightly to clear any obstructions. Carefully lower the tailpipe and remove it from under the vehicle. Be aware that some soot and carbon deposits may fall during removal.
6. 6

   Inspect and clean mating surfaces
   Inspect the muffler outlet pipe for damage, excessive corrosion, or cracks. Use a wire brush to clean the outer surface of the muffler outlet pipe where the new tailpipe will connect. Remove all rust, carbon buildup, and old gasket material to ensure a proper seal. Inspect both rubber hangers; replace if torn, cracked, or severely deteriorated.
7. 7

   Install new tailpipe
   Position the new tailpipe under the vehicle and align it with the muffler outlet pipe. Slide the tailpipe forward onto the muffler outlet, ensuring at least 2-3 inches of overlap. The tailpipe should slide on with moderate resistance. Position the tailpipe so it will align with both hanger locations.
8. 8

   Install exhaust clamp
   Position the new band clamp over the joint where the tailpipe connects to the muffler outlet. Center the clamp over the joint with equal coverage on both pipes. Install the clamp bolt and nut finger-tight only at this stage to allow for final adjustment.
9. 9

   Connect exhaust hangers
   Install the front rubber hanger first by pushing the grommet onto the support bracket stud. Use a pry bar or hanger tool if needed for leverage. Repeat for the rear hanger. Ensure both hangers are fully seated on their studs and the tailpipe is hanging at the correct height and angle.
10. 10

    Adjust tailpipe alignment
    Verify the tailpipe exits behind the rear bumper with approximately 1-2 inches of clearance from the bumper, frame, and rear axle. The pipe should hang level and not contact any body panels or suspension components. Make small adjustments by loosening the clamp and rotating or sliding the tailpipe as needed.
11. 11

    Tighten exhaust clamp
    Once alignment is correct, tighten the band clamp nut using the appropriate socket and ratchet (commonly 13mm or 15mm). Tighten firmly until the clamp band begins to compress and form to the pipe. Follow the clamp manufacturer's torque specification if using a torque wrench, as values vary by clamp type. Do not over-tighten as this can damage the clamp or crush the pipes.
12. 12

    Final inspection
    Perform a final visual inspection of the entire tailpipe installation. Verify the clamp is tight, both hangers are properly engaged, and the pipe has adequate clearance from all surrounding components. Check that the tailpipe tip extends slightly beyond the vehicle body and is positioned aesthetically.

Reassembly

1. No disassembly of other components required for this procedure

Verification

• Lower the vehicle to the ground and remove jack stands
• Start the engine and allow it to idle
• Walk to the rear of the vehicle and verify exhaust is exiting the tailpipe normally with no unusual sounds
• Listen carefully for any exhaust leaks at the clamp connection - a hissing or ticking sound indicates a poor seal
• Check for visible exhaust smoke escaping from the clamp area
• Rev engine slightly to 1500-2000 RPM and recheck for leaks
• After a short test drive, recheck tailpipe alignment and clamp tightness while exhaust is still warm

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