Exhaust Leak-Muffler

[GaryT]

2019 Big Horn, 5.7 eTorque. Noticed the truck sounding louder on cold starts over the last couple of weeks, getting a little worse daily. Finally got a time where I could cold start and check the exhaust, and the gasket between the converter pipe and the muffler is leaking. Exhaust hasnt been touched since it left the factory. Has anyone else run into this? It hardly seems worth the effort to get it fixed under warranty but the only source I have found for the gasket is through OEM sellers.

 

[Dusty1948]

2019 Big Horn, 5.7 eTorque. Noticed the truck sounding louder on cold starts over the last couple of weeks, getting a little worse daily. Finally got a time where I could cold start and check the exhaust, and the gasket between the converter pipe and the muffler is leaking. Exhaust hasnt been touched since it left the factory. Has anyone else run into this? It hardly seems worth the effort to get it fixed under warranty but the only source I have found for the gasket is through OEM sellers.

Yes, I've seen one. I'm betting that the only thing holding the two flanges together on your truck were self tapping bolts. Is that correct?

There should be two bolts and two nuts at the flange connection. I think a number of '19s left the factory without the nuts.

Anyway, should be a warranty repair.

Best regards,
Dusty
2019 Ram 1500 Billet Silver Laramie Quad Cab 2WD, 5.7 Hemi, 8HP75, 3.21 axle, 33 gallon fuel tank, factory dual exhaust, 18” wheels. Build date: 03 June 2018. Now at: 038188 miles.

 

[GaryT]

Youre absolutely right, didnt notice before, but there are no nuts.

 

[STR]

Just saw a thread on here yesterday of someone complaining about that gasket, so I you’re not the only one... Simple fix under warranty.

 

[silver billet]

Can one of you kind souls post a pic or two of this? Maybe one showing "from a distance" where I can locate that flange, and another close up showing where the bolts are supposed to be? I think mine has had a factory exhaust leak from day one (it certainly has the most "airy" sound in a vehicle I've ever owned) and if bolts are missing from the factory that might explain the noise in my truck as well.

 

[Dusty1948]

Can one of you kind souls post a pic or two of this? Maybe one showing "from a distance" where I can locate that flange, and another close up showing where the bolts are supposed to be? I think mine has had a factory exhaust leak from day one (it certainly has the most "airy" sound in a vehicle I've ever owned) and if bolts are missing from the factory that might explain the noise in my truck as well.

I don't have an actual picture (it's after 11 PM here), but the flange connection in question is the one that's between the front of the muffler and the exhaust pipe. The parts list shows a gasket, two bolts and two corresponding nuts holding the flange connection together.

Best regards,
Dusty
2019 Ram 1500 Billet Silver Laramie Quad Cab 2WD, 5.7 Hemi, 8HP75, 3.21 axle, 33 gallon fuel tank, factory dual exhaust, 18” wheels. Build date: 03 June 2018. Now at: 038318 miles.

 

[GaryT]

This is the flange, it is located in front of the muffler about mid way of the rear door. I tried to tighten it but I can feel it trying to break so ill have to check to see if this falls under the bumper to bumper or the powertrain warranty since I am at 40k miles.

 

[silver billet]

Thanks GaryT, might just be me but I find that absolutely terrifying. In this case it's just exhaust, but cars and trucks should not be leaving the factory with nuts missing from the bolts. That might explain a few other clunks I hear in my truck as well.

 

[silver billet]

So I just popped my head under my truck. Judas...

Missing the nuts as well. My seal looks kind of good yet, do you guys think this might be the source of exhaust noise I hear?

And when I bring it in for warranty fix, should I "demand" a new gasket as well?

 

[GaryT]

Upon closer inspection, my lower bolt is broken, the two pieces of the flange will move up and down but the bolt is clearly separated. The dealer is saying its a bumper to bumper warranty item, I am at 40k so its on me to fix it. Lovely.

 

[silver billet]

@Dusty1948 How sure are you that nuts are required? Is it possible that these bolts screw into the flange which has the thread already in the flange, thereby not requiring nuts on the end? I didn't try to turn the bolts, but if the flange is mostly still together like it is in my case, then there has to be something that is keeping the two halves together?

 

[mikeru82]

The stock exhaust on my 2020 Laramie didn't have nuts on those fasteners. The flange on the muffler is threaded. I've since added an aftermarket exhaust so I no longer have the factory muffler to show a pic. I'll take a look at our 2020 Limited when I get home from work.

 

[GaryT]

Ill post a pic later, but this bolt was rusted through about half of the diameter of the threaded portion. Sure didnt expect to see this from a 1 year old truck.

 

[Dusty1948]

@Dusty1948 How sure are you that nuts are required? Is it possible that these bolts screw into the flange which has the thread already in the flange, thereby not requiring nuts on the end? I didn't try to turn the bolts, but if the flange is mostly still together like it is in my case, then there has to be something that is keeping the two halves together?

You will find, I'm sure, that the flange is indeed threaded. It's possible that engineering changed their mind at one point to eliminate the nuts and just rely on the bolt to keep it tight. The current parts list page clearly shows nuts and includes a part number (6101696).

I've only seen one of these so far and I can tell you the gasket, bolts and nuts were ordered for the repair. I can also tell you that a tech. has informed me that he has yet to see nuts installed at that flange connection from the factory.

I'm also being told that replacing those bolts is a real PITA.

Best regards,
Dusty
2019 Ram 1500 Billet Silver Laramie Quad Cab 2WD, 5.7 Hemi, 8HP75, 3.21 axle, 33 gallon fuel tank, factory dual exhaust, 18” wheels. Build date: 03 June 2018. Now at: 038390 miles.

 

[GaryT]

This was the culprit. Dusty is correct, it wasnt easy, had about 90 minutes wrapped up in this but it now has a larger 8.8 bolt with a nut, the truck is quiet again.

 

[Dusty1948]

This was the culprit. Dusty is correct, it wasnt easy, had about 90 minutes wrapped up in this but it now has a larger 8.8 bolt with a nut, the truck is quiet again.

Nice. From what I can tell the gasket is not dealer stock. Did you replace it, too?

Regards,
Dusty
2019 Ram 1500 Billet Silver Laramie Quad Cab 2WD, 5.7 Hemi, 8HP75, 3.21 axle, 33 gallon fuel tank, factory dual exhaust, 18” wheels. Build date: 03 June 2018. Now at: 038390 miles.

 

[GaryT]

Didnt replace the gasket, but it sealed. Being a metal gasket it didnt appear to have any hot spots or damage so i'll run it as is and see how it holds up.

 

[Dookie]

No nuts here, 2019 July 2019 build. According to the above part number, it is a M10 x 1.5, going to pick up a few all metallic locking ones from Lowes or wherever and add them myself.

 

[Dookie]

Picked these up at Lowes for ~$3.00/pair. Can confirm the M10 x 1.5 works, 17mm or 11/16 wrench. Will install "backwards" because not many threads there to hold the locking area.

 

[Dusty1948]

Picked these up at Lowes for ~$3.00/pair. Can confirm the M10 x 1.5 works, 17mm or 11/16 wrench. Will install "backwards" because not many threads there to hold the locking area.
View attachment 66643
View attachment 66644

Yes, the bolts they ended up using are shorter than the ones called out in the parts list. Probably because they felt nuts weren't needed, so why install a longer bolt.

Let us know how the Hillman hardware worked for you.

Best regards,
Dusty
2019 Ram 1500 Billet Silver Laramie Quad Cab 2WD, 5.7 Hemi, 8HP75, 3.21 axle, 33 gallon fuel tank, factory dual exhaust, 18” wheels. Build date: 03 June 2018. Now at: 038990 miles.