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.
