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Dodge Ram 2002-2008: The Ultimate Exhaust Guide

Are your tired of your truck being limited in how it sounds? Then take some time to check out the following aftermarket exhaust systems for your Dodge Ram, and how to install it.

By Neftali Medina - July 21, 2015
Contributors: Realtrucks, Autoanything, Borla, Smithtyres

This article applies to the 3rd Generation Dodge Ram (2002-2008)

The factory equipped exhaust on your Ram was primarily designed to hush the engine note, and keep the cabin quiet. After years of dealing with salty roads, humidity, and high temperatures, the stock still on an exhaust will begin to rust away. You can consider it a wear and tear item, especially if you go off-roading and it gets torn up by big rocks. Oops! Well, it's time for an upgrade. With that said, stock life is for squares, and the best way to break free is with a wicked exhaust. Here are your options for turning up the decibels on your ride.

Table of Contents

Exhaust System Review

Aftermarket exhaust systems are made to increase the overall efficiency of an engine. The manufacturers listed here use mandrel bent tubing, high quality mufflers and glass packs to make some of the best kits on the market for a Dodge Ram. Stainless steel also plays a role in helping promote the longevity of the exhaust kit. So take your time and see which exhaust kit will provide the best sound you want.

Please note that the price is based on a 2002 Dodge Ram, so are subject to change according to year and trim level.
MagnaFlow
Flowmaster
Borla
MBRP
Price
 $800 $625 $1,100 $890
Quoted Power Gains
 10% 10% 15% 10%
Pipe Size
 2.5" to 3.5" 2.5" to 3" 3" to 2.25" 3"
Single/Dual exit Pipe
 Dual Exit Single/Dual Exit Dual Exit Dual Exit
Warranty
 Limited Lifetime Limited Lifetime 1,000,000 miles Limited Lifetime
Best Quality: Borla

Best Value: MangaFlow

MagnaFlow Cat-Back Stainless Performance Series

K&N Air Filter for 5.4L V8 F-150

Price – $800

Quoted Power Gains – 10%

Piping Diameter – 2.5" Inlet/3" Outlet; 3.5" Tips

Single or Dual Exit Pipe – Dual Exit Pipe

Warranty – Limited Lifetime

MagnaFlow has been in the business for years, producing long lasting quality exhaust systems. Their Cat-back Stainless Performance series offers Ram drivers a nice deep sounding tone, with mandrel bent tubing and a stainless steel finish. The piping diameter ranges from 2.5", starting at the dual-exit muffler all the way to 3.5" at the tail-pipes. Although performance gains may differ from truck to truck, you are bound to experience at least a 10% increase in both horsepower and torque. Recommended for those looking for a great exhaust without hurting their bank.

Flowmaster

Spectre Air Filter for 4.6L V8 F-150

Price – $625

Quoted Power Gains – 10%

Piping Diameter – 2.5" Inlet/3" Outlet; 3" Tips

Single or Dual Exit Pipe – Single/Dual Exit Pipe

Warranty – Limited Lifetime for stainless; 3-year for aluminzed piping

Flowmaster is not anything to balk at; they hold their own in terms of performance and styling. A standard exhaust kit from Flowmaster is pieced together by certified technicians, not only to get a quality muffler, resonator glass packs, but so each component is able to compliment each other and improve the overall performance of the system. You can choose from either dual or single exit mufflers to fit your liking. Flowmaster offers a limited lifetime warranty for its stainless steel kits, which covers any manufacturer defects or premature failures. However, the con to a Flowmaster system is its longevity, since after 4 to 5 years, the exhaust system's sound begins to deteriorate, which tends to be a result of the packing and insulation of the mufflers blowing out. Recommended for those who would not mind replacing the kit in a few years.

Borla

Air Raid Air Filter

Price – $1,100

Quoted Power Gains – 15%

Piping Diameter – single 3" into muffler dual 2.25" out

Single or Dual Exit Pipe – Dual Exit Pipe

Warranty – 1,000,000 Mile Warranty

These kits are arguably the best on the market; however, they do not come cheap. Each pipe is mandrel bent to perfection, allowing for a perfect flowing exhaust. Each kit is built from authentic 300-series austenitic stainless steel, which lasts much longer than the T-400 series counterparts used by other exhaust companies. Their straight through multi-core technology provide an increase in power, fuel economy, and create a nice deep tone to make anyone smile uncontrollably. Recommended for those who don't mind busting their bank for something that won't need replacing ever again.

MBRP Cat-Back Pro Series

Price – $890

Quoted Power Gains – 10%

Piping Diameter – 3"

Single or Dual Exit Pipe – Dual Exit Pipe

Warranty: Limited Lifetime

MBRP is known for their diesel exhaust systems, which provide deep tones while supplementing the engine. The exhaust kits are made from T-304 stainless steel, so do not expect the same quality as Borla. However, it still does provide a solid system for the price. The Cat-back pro series is also backed by a limited lifetime warranty. Recommended for those looking for a mid-tier exhaust system.

Pro Tip

In terms of performance, a new exhaust system will not make a huge difference on a stock engine. However, when combined with other upgrades, including exhaust headers and a better flowing intake, you will see more comprehensive gains. So take the time to look at which system will provide you with the best present and future outcome you want for your ride.

How to Replace Your Exhaust System

Now that you have picked the exhaust that best fits your needs, you can go ahead and install it yourself. Below are the steps needed to replace the exhaust system in your Dodge Ram.

Materials Needed

  • Phillips screwdriver
  • Socket set
  • Jack and jack stands
  • Torque wrench
  • Welder
  • Reciprocating saw
  • Penetrating oil

Step 1 – Lift and support the truck

Use a jack to lift the chassis of the truck up, and support it in the air using jack stands.

Figure 1. Raise and support the truck.

Step 2 – Remove the old exhaust

Each kit varies according to where you remove the exhaust system. Some will require you to cut off a section of the piping, while others may just attach to it. If you are cutting the pipe, use a reciprocating saw to slice evenly through it. Then begin to remove the stock exhaust components.

  • Spray penetrating oil onto all the old joints.
  • Loosen each clamp.
  • Remove each pipe from the rubber hangers.
  • Figure 2. Spray some penetrating oil onto the old system.
  • Figure 3. Slide out each piece from their hangers.
  • Figure 4. Remove the old muffler.

Step 3 – Install the adapter pipe and muffler

Slide the adapter pipe onto the old stock exhaust pipe, and then install two hangers on of it. Hand-tighten the hanger from the side of the adapter to the stock pipe.

Figure 5. Install the adapter pipe.

With the pipe in place, attach the new muffler.

Figure 6. Muffler installed.

Step 4 – Attach the new pipes

  • Slide each new pipe into the rubber hangers.
  • Attach both pipes to the muffler and slide the clamps on top.
  • Figure 7. Slide the new pipes into the rubber hangers.
  • Figure 8. Attach each pipe to the muffler.

Step 5 – Install the tail pipes and tips

  • Install a new support bracket onto the chassis.
  • Install the new tail-pipes onto the muffler, and hand-tighten each clamp.
  • Figure 9. Install support bracket.
  • Figure 10. Install each new tail-pipe.

Step 6 – Tighten the exhaust clamps and weld them in place

  • Torque down each support clamp to 60 ft. lbs.
  • Weld them in place.
  • Figure 11. Tighten each exhaust clamp.
  • Figure 12. Weld each clamp in place.

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