Dodge Ram 1994-2001: Exhaust Modifications and How-to Super Article

This article applies to the Dodge Ram (1994-2001).

Aftermarket exhaust systems are extremely popular upgrades for truck owners, whether you are looking to unleash some extra power or you just enjoy the sweet sound of a big engine. There are a lot of options out there, with each meeting different needs and wants. No matter which option you choose, installing an aftermarket cat-back exhaust is a pretty easy DIY, while axle-back options might require the services of a professional.

Exhaust Overview

When you're making the decision of which exhaust system to go with, there are tons of great options. Cat-back exhaust systems are by far the easiest and most popular option over the more complicated axle-back setups, but won't provide the same power boost. Headers are a popular option as well since they free up extra horsepower and aren't too difficult to install.

As shown above, there are several options for aftermarket exhausts, but which one is the best? Years ago, axle-back exhausts were your only option, and generally had to be custom fit to your application by a professional. Cat-back exhausts have grown in popularity because you can install them yourself without having to bend pipes, and they are affordable to boot. Either way you go, a set of headers is a nice addition if you want to increase your truck's exhaust flow even more.

Headers

Price – $200-500

DIY Level – Easy

Rating – Recommended

Power – Good

Headers bolt in place of your stock exhaust manifolds, increasing airflow and power at the same time. Headers are also one of the easier bolt on modifications you can make to your truck. Modern headers are pre-bent to fit your specific application, which is a huge improvement over past years, when they had to be custom bent and welded by a professional. When used in tandem with an aftermarket exhaust, they provide a great upgrade over stock, restrictive manifolds and pipes. Recommended. Headers are inexpensive, easy to install, and provide big power increases over stock. They make a ton of sense as a complimentary upgrade to an aftermarket exhaust system.

Cat-Back Exhaust

Price – $500-850

DIY Level – Moderate

Rating – Recommended

Power – Good

There was a time when if you wanted to upgrade your exhaust, you took it to a professional and they bent and welded pipes to fit. You can still do that, but cat-back exhaust systems are a very economical way to do it yourself with little trouble. You won't get the power gains a custom axle-back system might provide, but many states don't allow the removal of catalytic converters for street use anyway. That means, for many people, a cat-back system is the only way to go. Regardless, you can get a nice boost in power and an aggressive exhaust tone after installing one. Recommended. Cat-back exhaust systems are easy to install and provide a nice boost in power and sound over stock exhaust pipes.

Axle-back Exhaust

Price – $500-2,000

DIY Level – Hard

Rating – Not Recommended

Power – Excellent

If you want the absolute best power and sound and don't have to worry about the legality of eliminating catalytic converters, an axle-back exhaust system is the way to go. While you used to have to have a professional make a custom exhaust out of pipe, there are now tons of options in the aftermarket for kits you can install yourself. This is a more complicated job that results in a minimal gain in benefits over a cat-back system, however, making it a poor option for most. Not Recommended. Axle-back exhausts are only legal in certain states for on-road use, are more difficult to install, and provide a minimal upgrade over cat-back systems.

How to Install Headers and a Cat-back Exhaust

Installing headers and a cat-back exhaust on your Ram will give you a noticeable increase in horsepower and a nice, aggressive exhaust sound. They are also pretty easy to install and relatively affordable, making them great upgrades for most.

Step 1 – Remove exhaust manifolds

Pop the hood and use zip ties to hold any tubing or wiring out of the way of the manifold. Remove the two nuts holding the middle of the manifold in place using the 1/2" socket. Use a jack and block of wood to support the bottom of the manifold, then remove the flange nuts. Use a gear wrench to remove the manifolds from the factory exhaust. Remove the manifold.

Step 2 – Install headers

Set the header gaskets in place first. Place a bead of Permatex Copper Core RTV around the dome of the headers. Slide the headers into place and screw the nuts on the studs, but don't tighten them just yet. Tighten the inside nuts first, then the outside for a proper seal. Connect the flanges and tighten. Torque the header bolts to 21 ft/lbs.

Step 3 – Remove stock exhaust

Jack the rear of the truck up and support it on jack stands. Spray all of the exhaust hanger bolts and rubber flanges with penetrating oil and let it sit for 15 minutes. Remove the bolts and hangers. Cut the exhaust pipes at the mufflers and pull the old exhaust out of the truck.

(Related Article: How to Jack Up Your Truck - Dodgeforum.com)

Step 4 – Install cat-back exhaust

Install the end pipe using the 2.5" band clamp, lining up the cuts in the pipe with the factory studs. Set the 3.5" band clamp in place, along with the muffler. Install the hanger brackets and passenger side tail pipe, connecting it to the muffler. Install the over axle pipe on the driver's side with a 2.5" band clamp. Install the frame hanger on the driver's side. Install the driver's side tail pipe and 2.5" band clamp and hanger. Install the exit pipes. Level out the muffler and check all clearances, then torque all band clamps to 60 ft/lbs. Install exhaust tips and adjust to your liking.

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