Dodge Ram Truck 1500-2500-3500. Manual — part 1431

5.7L ENGINE

1. Install catalytic converter to exhaust clamp (4) on

catalytic converter (3) and position into exhaust
pipe (5).

2. Make sure the alignment tang on catalytic con-

verter (3) is fully seated in the notch on the
exhaust pipe (5).

3. Install catalytic converter to exhaust manifold bolts

(2) and nuts (1).

4. Tighten catalytic converter to exhaust manifold

bolts (2) to 31 N·m (23 ft. lbs.).

5. Tighten catalytic converter to exhaust pipe clamp

nuts (4) to 52.2 N·m (40 ft. lbs.) torque.

6. Check the exhaust system for contact with the

body panels. A minimum of 25.4 mm (1.0 in.) is
required between the exhaust system components
and body/frame parts. Make the necessary adjust-
ments, if needed.

7. Lower the vehicle.

8. Start the engine and inspect for exhaust leaks.

Repair exhaust leaks as necessary.

5.9L ENGINE DIESEL

NOTE: The catalytic converter to exhaust manifold
clamp is not reusable. Always use a new clamp
when reinstalling the catalytic converter.

1. Position the catalytic converter (4) onto the front

exhaust pipe (2) until the alignment tab is seated
into the alignment slot of the catalytic converter (4).

2. Install catalytic converter (4) into the exhaust pipe

(6) onto the until the alignment tab is seated into
the alignment slot of exhaust pipe (6).

3. Position front exhaust pipe (2) onto turbocharger

and install new clamp (1). Tighten the nuts to 11
N·m (100 in. lbs.) torque.

4. Install the exhaust clamp (5) at the exhaust pipe

(6) and catalytic converter (5) connection. Tighten
the clamp nuts to 54.2 N·m (40 ft. lbs.) torque.

5. Check the exhaust system for contact with the

body panels. A minimum of 25.4 mm (1.0 in.) is
required between the exhaust system components
and body/frame parts. Make the necessary adjust-
ments, if needed.

6. Lower the vehicle.

7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.

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EXHAUST SYSTEM

DR/DH

8.3L ENGINE

1. Make sure catalytic converters (3, 6) and mufflers

(5) are free of burrs.

2. Insert RH catalytic converter (3) into muffler (5).

3. Make sure the alignment tang on the catalytic con-

verter (3) seats in the alignment slot on the muffler
(5).

4. Position the catalytic converter (3) to the exhaust

manifold. Install and hand tighten bolts (2) , retain-
ers and nuts (1).

5. Insert LH catalytic converter (6) into muffler (5).

6. Make sure the alignment tang on the catalytic con-

verter (6) seats in the alignment slot on the muffler
(5).

7. Position the catalytic converter (6) to the exhaust

manifold. Install and hand tighten bolts (2), retain-
ers and nuts (1).

8. Check the exhaust system for contact with the

body panels. A minimum of 25.4 mm (1.0 in.) is
required between the exhaust system components and body/frame parts. Clearance between catalytic converter
and frame is 15 mm (.59 inch). Make the necessary adjustments, if needed.

9. Tighten catalytic converter to exhaust manifold bolts (2) to 20.3 N·m (15 ft. lbs.) torque.

10. Tighten the clamp nuts to 54.2 N·m (40 ft. lbs.) torque.

11. Lower the vehicle.

12. Start the engine and inspect for exhaust leaks. and exhaust system. Repair exhaust leaks as necessary.

PIPE EXHAUST

REMOVAL

3.7L/4.7L/5.7L ENGINE

1. Raise and support the vehicle.

2. Saturate the bolts and nuts with heat valve lubri-

cant. Allow 5 minutes for penetration.

3. Remove exhaust pipe to manifold bolts, retainers

and nuts.

4. Remove the clamp nuts.

5. Remove the exhaust pipe.

DR/DH

EXHAUST SYSTEM

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5.9L DIESEL

1. Disconnect the battery negative cables.

2. Raise and support the vehicle on a hoist.

3. Saturate the bolts and nuts with heat valve lubri-

cant. Allow 5 minutes for penetration.

4. Remove the exhaust pipe-to-extension pipe clamp.

Separate the exhaust pipe and extension pipe.

5. Remove the exhaust pipe-to-turbocharger elbow

clamp.

6. Remove the exhaust pipe from the transmission

support.

8.3L ENGINE

1. Raise and support the vehicle.

2. Saturate the bolts and nuts with heat valve lubri-

cant. Allow 5 minutes for penetration.

3. Remove clamp nuts.

4. Remove exhaust pipe isolators.

5. Rotate the exhaust pipes to remove from the

muffle.

INSPECTION

Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with original equipment
parts, or equivalent. This will assure proper alignment with other parts in the system and provide acceptable exhaust
noise levels.

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EXHAUST SYSTEM

DR/DH

INSTALLATION

3.7L/4.7L/5.7L ENGINE

1. Position the exhaust pipe for proper clearance with

the frame and underbody parts. A minimum clear-
ance of 25.4 mm (1.0 in.) is required.

2. Position the exhaust pipe to manifold. Install the

bolts, retainers and nuts. Tighten the nuts to 31
N·m (23 ft. lbs.) torque.

3. Tighten the clamp nuts to 54.2 N·m (40 ft. lbs.)

torque.

4. Lower the vehicle.

5. Start the engine and inspect for exhaust leaks and

exhaust system contact with the body panels.
Adjust the alignment, if needed.

5.9L DIESEL

1. Install the exhaust pipe into the transmission sup-

port and onto the turbocharger flange.

2. Install

the

exhaust

pipe-to-turbocharger

elbow

clamp and tighten to 11 N·m (100 in. lbs.) torque.

3. Install the extension pipe and clamp to the exhaust

pipe using a new clamp and tighten the clamp nuts
to 54.2 N·m (40 ft. lbs.) torque.

4. Check the exhaust system for contact with the

body panels. A minimum of 25.4 mm (1.0 in.) is
required between the exhaust system components
and body/frame parts. Make the necessary adjust-
ments, if needed.

5. Lower the vehicle.

6. Connect the battery negative cables.

7. Start the engine and inspect for exhaust leaks.

Repair exhaust leaks as necessary.

DR/DH

EXHAUST SYSTEM

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