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Dodge Ram 2009-Present: Exhaust Manifold Bolt Issue

Broken exhaust manifolds bolts have become a common problem on 4th generation Dodge Rams. Dodge has improved on the bolts design, and owners are suggested to repair the problem before the bolts break. Otherwise, expensive bolt extraction and thread repair may be needed.

By Weston Chadwick - July 22, 2015
Contributors: TrueDogman

This article applies to the 4th Generation Dodge Ram (2009-Present).

Owners wondering whether their Ram has broken exhaust manifold bolts will most likely notice the accompanied ticking sound coming from the exhaust manifold(s). The noise comes from exhaust gases leaking past the manifold gasket, and if it becomes bad enough, can lead to lowered engine performance and fuel economy. The exhaust manifold bolts are subjected to high amounts of heat while the engine is running, particularly the rear cylinders. Expansion and contraction during heat cycles is not equal between the bolts, manifolds, and cylinder head, which is believed to be the primary reason for failure.

Owners are left paying the bill or repairing the problem themselves if their truck is out of warranty. The 2009 model years trucks carry an unlimited powertrain warranty, which covers the issue. Owners with 2010 and newer trucks typically have warranties that run out after 5 years/100,000 miles. The repair can be from $200 to $400 or more depending on whether the manifold and gaskets are also replaced. Dodge now installs new stainless steel bolts/studs (part number 6509544AA), which has proven somewhat successful permanently fixing the problem. Some owners still post about their second trip to the dealer for the same fix.

Component Breakdown

The Exhaust Manifold Bolts

The best case scenario when these break or corrode is to remove the bolt head if it cannot be turned with vice grips. This can be done with an air hammer or hammer/chisel. An alternate method is completed by threading the bolt with a dye and hot welding or cold welding (J-B Weld) a nut to the bolt. You can then turn it with a normal socket or wrench.

If the bolt breaks where it meets the cylinder head, you still have options. A bolt extractor can be used that works itself into the bolt, making it possible to turn. Extractors may also prevent damage to the cylinder head threads. Left-handed drill bits can also be used. When damage to the cylinder head threads, a heli-coil can be used to repair the damaged threads.

Replace the exhaust manifold gaskets if the manifold is removed.

Figure 1. Snapped exhaust manifold stud.

Common Questions

What Will the Exhaust Leak Sound Like?

The sound is described as a loud ticking that goes away after the engine is warmed (5-10 minutes).

Featured Video: Dodge Ram Broken Manifold Bolt

I am the Second Owner, Is My Truck Still Covered Under Warranty For This Repair?

Yes, it probably is. Check with your local dealer to verify.

My Dealer Is Telling Me My Truck Is Not Under Warranty, Even Though It's Within the Year and Mileage Amounts. What Can I Do to Dispute This?

In this situation it's best to talk to Dodge directly by phone or email.

Click on this link for the Dodge Contact Us homepage.

How Long Will This Repair Take?

If the exhaust manifold needs to be removed to access the broken bolt(s), it may take two or more hours.

Are There Any Tips to Completing This Job Myself?

Be prepared with the proper thread repair and bolt extraction tools. Soak the bolts with penetrating oil overnight. Use a torch to expand and soften up the metals before removal. Remove the wheel/fender liners for the best access to the exhaust manifolds. If the manifolds are removed, replace the gasket.

Figure 2. Using a bolt extraction tool.

How Do I Know Whether I Need to Replace the Exhaust Manifolds or Not?

Use a straightedge and feeler gauge to determine manifold warp. Measure from side to side and diagonally. Over .005" of warp may create an exhaust leak.

Technical Service Bulletins (TSB)

  • 11-002-11 02/17/20011 Exhaust System: Engine ticking sound in cold temperatures

Featured Video: Removing Broken Exhaust Manifold Bolts

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