So in trying to do a simple swap of my truck muffler with an AT3030 I hit a roadblock because it appears the stock piping is actually 2 3/4 inch rather than 3. I bought 3" torctite clamps and can't attach them... How are people getting these mufflers installed? I thought it would be an easy swap.

 

I welded mine and the couple other Hemi's I've done and ain't good about measuring, I just go get a couple reducers before I start, I know I'll use the extras at some point. I ain't never messed with clamps, but I think the pipe is 2.25 ID which would be 2.5 OD. The 3" STEPPED Torctite is the one you want...

 

I bought a 3" DMH Electric Exhaust cutout and had the same issue. The exhaust between the y pipe and the muffler is 2.75" OD. I had planned to use clamps to hold the cutout in place but due to the odd size, I had to take it to a custom exhaust shop. The 3" band clamps would not tighten to fill the gap.

 

Wish someone made this clear before I wasted money on 2 clamps =/.

Hopefully this thread serves to warn future buyers that muffler swaps aren't straightforward with the weird pipe sizing

 

The guy that does my exhaust confirmed that it was a 2.75" OD pipe. I had already bought the 3" cutout with y pipe. He had to cut the 3" y pipe that came with the cutout down the middle lengthwise (not the part that the valve attaches to). He then had to cut a piece of 2.75" pipe and make a notch in it. From there he welded the 3" y pipe to the notched out 2.75" pipe to complete the cutout.

Do the 2005s have a unique exhaust size?

 

I don't think it's unique I think most people just bring it to a shop to have it done and don't encounter the issue themselves. A lot of people claimed it was 3" piping without actually measuring themselves. I've even heard 2.5" from others, but plain and simple it's actually 2.75"

 

I actually could have sworn I bought a 3" to 2.5" reducer from the 3" collector to the pipe when I did the headers. Oh well, I've been wrong before...

 

Got it installed with an adapter. Cut the exhaust short before the resonator. This thing sounds MEAN! lol. I'll probably post a video once I get my longtubes and Y ordeal sorted out and installed

 

Videos are always welcomed.

With you living up north, would it have been a better idea to add the muffler AFTER you replaced the headers and Y pipe and whatever else OEM piping that was there. It might be rusting out?

 

The stock piping isn't doing all that bad really, if I'm not mistaken it's stainless from the factory. Sure it's got some surface rust but it's doing alright. Headers and Y should bolt right to it.