Cracked Exhaust? Really?

[dn325ci]

I kind of can't believe what I'm hearing but my 2019 Ram 1500 Laramie Sport is at the dealer right now, and I just learned both exhaust manifolds have a crack in them! I've owned the truck since February 2019, so it's been 25 months, and I drive above average miles so it's out of warrranty by miles, but above average miles does not crack exhaust manifolds. In fact a new vehicle should NOT have cracked exhaust manifolds. I've never even had an old vehicle with one exhaust manifold problem, let alone two. And they are telling me the bill is $2,100!

This is my very first Ram vehicle. For many years I've driven German cars, but the new design Ram 1500 convinced us we should buy our very first full size pickup ever. Is this a real thing? If so, I'm done with Ram.

 

[LimitedGRR]

I kind of can't believe what I'm hearing but my 2019 Ram 1500 Laramie Sport is at the dealer right now, and I just learned both exhaust manifolds have a crack in them! I've owned the truck since February 2019, so it's been 25 months, and I drive above average miles so it's out of warrranty by miles, but above average miles does not crack exhaust manifolds. In fact a new vehicle should NOT have cracked exhaust manifolds. I've never even had an old vehicle with one exhaust manifold problem, let alone two. And they are telling me the bill is $2,100!

This is my very first Ram vehicle. For many years I've driven German cars, but the new design Ram 1500 convinced us we should buy our very first full size pickup ever. Is this a real thing? If so, I'm done with Ram.

You could go with aftermarket manifolds which are better and you can probably get them installed for a fraction of the price. It’s not common but it’s happened enough to notice, especially the bolts breaking holding the manifolds to the block


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[LimitedGRR]

I kind of can't believe what I'm hearing but my 2019 Ram 1500 Laramie Sport is at the dealer right now, and I just learned both exhaust manifolds have a crack in them! I've owned the truck since February 2019, so it's been 25 months, and I drive above average miles so it's out of warrranty by miles, but above average miles does not crack exhaust manifolds. In fact a new vehicle should NOT have cracked exhaust manifolds. I've never even had an old vehicle with one exhaust manifold problem, let alone two. And they are telling me the bill is $2,100!

This is my very first Ram vehicle. For many years I've driven German cars, but the new design Ram 1500 convinced us we should buy our very first full size pickup ever. Is this a real thing? If so, I'm done with Ram.

It’s not unique to the new rams. It’s happened to older engines too but still uncommon


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[Scap]

Definitely time to consider a set of headers.

 

[mikeru82]

Exhaust manifolds can and do crack on other brands of vehicles, not just Ram LOL. I've owned many older cars that had that problem. Hondas, GM's, Mitsubishi, and others. I'm sorry to hear this won't be covered under warranty for you, but maybe it's time to look into a set of headers, like Scap suggested.

 

[Ellisstrong]

I have a set of factory manifolds in Atlanta

 

[Billy James]

I'm curious. What led the dealership to look at the exhaust manifolds? Was it noise? I have a feeling mine may be cracked because it sounds like an exhaust leak and I can sometimes smell exhaust at the front of the vehicle. Mine isn't real loud; but noticeable.

 

[UnloosedChewtoy]

I kind of can't believe what I'm hearing but my 2019 Ram 1500 Laramie Sport is at the dealer right now, and I just learned both exhaust manifolds have a crack in them! I've owned the truck since February 2019, so it's been 25 months, and I drive above average miles so it's out of warrranty by miles, but above average miles does not crack exhaust manifolds. In fact a new vehicle should NOT have cracked exhaust manifolds. I've never even had an old vehicle with one exhaust manifold problem, let alone two. And they are telling me the bill is $2,100!

This is my very first Ram vehicle. For many years I've driven German cars, but the new design Ram 1500 convinced us we should buy our very first full size pickup ever. Is this a real thing? If so, I'm done with Ram.

A couple of points...

1. You have over 60k miles? Just making sure you're not talking over 36k miles, and the dealership has fed you a line about powertrain warranty not covering exhaust manifolds. Many have tried that lie on cracked manifolds for 4th gens under 5 year/60k. A few fessed up and gave in after being shown the warranty book, but some still refused. In those latter cases, people were able to report the dealer to FCA (not sure that actually did anything) and take it to a different dealer that would honor the warranty. Page 9 of the warranty book (screenshot below).

And again, that is assuming you're not over 60k.

2. If you are over 60k, as others suggested, I would instead go with a reputable exhaust shop, and purchase some decent aftermarket shorty headers to replace the manifolds, it should be cheaper than $2.1k. Some decent shorty headers (either ceramic coated 409 stainless or plain 304 stainless) would cost you around $700-$900, give or take. Even after some labor numbers from a decent exhaust shop, you should be under $2k, and you'd have better power.

3. One issue and you're done? Even the most reliable products occasionally have issues, its frequently just luck of the draw. Stick with it man, these trucks are fantastic.

 

[RamCares]

I kind of can't believe what I'm hearing but my 2019 Ram 1500 Laramie Sport is at the dealer right now, and I just learned both exhaust manifolds have a crack in them! I've owned the truck since February 2019, so it's been 25 months, and I drive above average miles so it's out of warrranty by miles, but above average miles does not crack exhaust manifolds. In fact a new vehicle should NOT have cracked exhaust manifolds. I've never even had an old vehicle with one exhaust manifold problem, let alone two. And they are telling me the bill is $2,100!

This is my very first Ram vehicle. For many years I've driven German cars, but the new design Ram 1500 convinced us we should buy our very first full size pickup ever. Is this a real thing? If so, I'm done with Ram.

Hi,

We responded to your PM, please take some time to review it and get back with us at your earliest convenience.

Rob
Ram Cares

 

[dn325ci]

I'm curious. What led the dealership to look at the exhaust manifolds? Was it noise? I have a feeling mine may be cracked because it sounds like an exhaust leak and I can sometimes smell exhaust at the front of the vehicle. Mine isn't real loud; but noticeable.

It started some time ago before the warranty mileage expired sounding like maybe a small exhaust leak that would go away as the vehicle warmed up. It was a little annoying, but it didn't seem to be getting worse and I thought I could live with it, rather than have what I knew would be a very invasive teardown to solve what seemed to be a small problem. Then recently it started getting dramatically worse, especially at startup, but now all the time. Now, I obviously greatly regret not taking it in when I first heard the small sound. It's a cautionary tale, guys.

 

[dn325ci]

A couple of points...

1. You have over 60k miles? Just making sure you're not talking over 36k miles, and the dealership has fed you a line about powertrain warranty not covering exhaust manifolds. Many have tried that lie on cracked manifolds for 4th gens under 5 year/60k. A few fessed up and gave in after being shown the warranty book, but some still refused. In those latter cases, people were able to report the dealer to FCA (not sure that actually did anything) and take it to a different dealer that would honor the warranty. Page 9 of the warranty book (screenshot below).
View attachment 87818
And again, that is assuming you're not over 60k.

2. If you are over 60k, as others suggested, I would instead go with a reputable exhaust shop, and purchase some decent aftermarket shorty headers to replace the manifolds, it should be cheaper than $2.1k. Some decent shorty headers (either ceramic coated 409 stainless or plain 304 stainless) would cost you around $700-$900, give or take. Even after some labor numbers from a decent exhaust shop, you should be under $2k, and you'd have better power.

3. One issue and you're done? Even the most reliable products occasionally have issues, its frequently just luck of the draw. Stick with it man, these trucks are fantastic.

Thanks for the great info @UnloosedChewtoy. I am above 60K miles now, unfortunately. I drive quite a bit, usually with just me, a briefcase and a 22" roller suitcase on board. I did not anticipate having a $2,100 repair on a 25 month old truck. I guess you could conclude I need to find a manufacturer with a longer warranty, but I don't accept that line of logic. I've bought many (too many) vehicles in 36 years of driving, typically imports. I have NEVER had a $2,100 repair on two year old car. In fact, I've never had a $2,100 repair on a 5 year old car that wasn't accident-related.

I started my career in manufacturing engineering, and a cracked casting is not due to above average mileage. A cracked casting is due to bad casting material, bad casting processes, or bad casting design. 99% it is one of those things.

The work on the truck by the dealer is already done, though I haven't picked it up.

 

[theblet]

Where are people seeing these cracks? Sometimes I think i hear an exhaust tick. Might have to take a look

 

[dn325ci]

Where are people seeing these cracks? Sometimes I think i hear an exhaust tick. Might have to take a look

@theblet the cracks are in the exhaust manifold bolted to the block on either side. These are cast iron pieces. Castings should not crack unless there is one of the 3 mentioned issues in play. Reading some threads on others efforts to diagnose, it would probably be difficult to get a good look without a remote camera or some visual aid.

BTW, I did share an exchange with @RamCares so hopefully they can support me here. Castings are not wear items. This is not an issue that should occur outside of a manufacturing defect.

 

[GerryS]

I can't believe that it is not defective if both of them cracked. That's ridiculous.

Gerry

 

[UnloosedChewtoy]

@theblet the cracks are in the exhaust manifold bolted to the block on either side. These are cast iron pieces. Castings should not crack unless there is one of the 3 mentioned issues in play. Reading some threads on others efforts to diagnose, it would probably be difficult to get a good look without a remote camera or some visual aid.

BTW, I did share an exchange with @RamCares so hopefully they can support me here. Castings are not wear items. This is not an issue that should occur outside of a manufacturing defect.

I can't believe that it is not defective if both of them cracked. That's ridiculous.

I do not think the issue here is whether it is a manufacturer defect or not. It clearly is. The issue is the warranty period.

Sometimes in weird situations like this (I'd venture to say there are not that many folks that have that many miles on a 2 year old truck), mother Chrysler will offer to cover it as a one time courtesy, or to pay 50% (or some other percentage) of the cost. Hopefully they help you out here.

Warped exhaust manifolds are semi-common on trucks for the past decade or so, not unique to Hemis. I've heard or read about them on Fords and Chevys as well. If you look at the design of them, its a little clear as to why... they're basically just logs with holes for the exhaust to go in and out. If they warp, they usually do so at the back near where they meet the exhaust pipe. The break off the rear studs/bolts as well, and leak (sometimes sealing back up after warming up).

However, cracked manifolds are definitely not normal, I'd say.

 

[dn325ci]

Warped exhaust manifolds are semi-common on trucks for the past decade or so, not unique to Hemis. I've heard or read about them on Fords and Chevys as well. If you look at the design of them, its a little clear as to why... they're basically just logs with holes for the exhaust to go in and out. If they warp, they usually do so at the back near where they meet the exhaust pipe. The break off the rear studs/bolts as well, and leak (sometimes sealing back up after warming up).

However, cracked manifolds are definitely not normal, I'd say.

I may be reading it wrong, but the way you say it sounds like you're OK with it. Where else in the auto industry is even warped exhaust manifolds acceptable? They are not acceptable, and are exceedingly rare elsewhere. And in 36 years of driving and many, many cars & SUVs owned, I have never had even a warped manifold before. How about you?

 

[LaxDfns15]

Go ask the Titan communities about their manifolds. I know forums are a small subset of truck ownership, but I'd say over 50% of Titan owners on the forums have/had cracked manifolds, including myself.

You keep talking about a 2 year old truck. Your engine and mechanical components don't feel like they're 2 years old. They feel like they're 5+ years old if you're over 60k miles. Granted, that's still not an old vehicle, but you have to look at mileage and not age. That's like saying someone that's 30 years old that ran a marathon every year for the last 10 years should feel the same as someone that hasn't at the same age.

 

[UnloosedChewtoy]

I may be reading it wrong, but the way you say it sounds like you're OK with it. Where else in the auto industry is even warped exhaust manifolds acceptable? They are not acceptable, and are exceedingly rare elsewhere. And in 36 years of driving and many, many cars & SUVs owned, I have never had even a warped manifold before. How about you?

I've driven for a bit over half as long as you, and yes, I've seen cases of warped manifolds on multiple vehicles. I'm sure your other vehicles have had issues (not manifolds) that the truck will not have. LaxDfns15 makes some good points above as well.

Definitely not OK with it. No reason to throw attitude around, we get you're upset about it. I simply offered some background to the effect that it is not a super-rare/never heard of issue, and some advice/hopes.

 

[dn325ci]

Go ask the Titan communities about their manifolds. I know forums are a small subset of truck ownership, but I'd say over 50% of Titan owners on the forums have/had cracked manifolds, including myself.

You keep talking about a 2 year old truck. Your engine and mechanical components don't feel like they're 2 years old. They feel like they're 5+ years old if you're over 60k miles. Granted, that's still not an old vehicle, but you have to look at mileage and not age. That's like saying someone that's 30 years old that ran a marathon every year for the last 10 years should feel the same as someone that hasn't at the same age.

Wow, I can’t believe your defending this defect. I don’t know anything about Titans but since Titans have a problem, you’re Ok with it? Castings are not wear items. Mileage isn’t the issue. Frankly, I’d argue I’ve had fewer thermal cycles due to fewer start stops so my case is less strenuous on a casting. I’m not trying to be insulting or adversarial at all. I’m surprised you have that level of low expectations. It’s not what I think most buyers expect. Whatever happened to tough, reliable trucks? I guess you’re ok with that not being Ram.

 

[Finn5033]

@dn325i

I’ve read this whole thread, nobody is saying they are ok with this. They are just pointing out that although cracked manifolds are not common, it’s not as if it has never happened before. They are just pointing out that this isn’t just a Ram problem. They just don’t want to see you give up on your truck because of this. They are great trucks, and it would be a shame to see you dump it over this issue