Exhaust System: Other RAM Pickup 3500

Catalytic Converter

Look at the stainless steel body of the Catalytic Converter assembly, inspect for bulging or other distortion that could be a result of overheating. Inspect for

1. Indiction of exhaust gas leakage such as soot trails.
2. Temperature sensor wiring for damage
3. Joint misalignment
4. Denting of greater then 6.3 mm (0.25 in.)
5. Outer shell torn, cracked or otherwise damaged
6. Loose or damaged core

3.7L/4.7L/5.7L ENGINE

1. Install RH catalytic converter to exhaust clamp (4) on RH catalytic converter (3) and position into exhaust pipe (5).
2. Install and hand tighten RH catalytic converter to exhaust manifold bolts (2).
3. Install c-clip nut (1) and bolt (2) to converter (3) to manifold.
4. Tighten catalytic converter to exhaust manifold bolts (1) to 31 N.m (23 ft. lbs.).
5. Tighten all clamp nuts (4) to 52.2 N.m (40 ft. lbs.) torque.
6. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed.
7. Check to ensure you have at least 25 mm clearance to oil pan.
8. Plug in O2 sensor wiring.
9. Lower the vehicle.
10. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.

Scheme 25

1. Position the DOC onto the turbocharger with the clamp (1) facing down as shown in illustration. Install the clamp (1) finger tight. 1 - TUBING SUPPORT BRACKET 5 - DOC TO NOx ABSORBER CATALYST (NAC) FLANGE 2 - FLEXIBLE PRESSURE DIFFERENTIAL TUBING 6 - NAC 3 - TURBOCHARGER CLAMP 7 - NAC TO DPF FLANGE 4 - DIESEL OXYGEN CATALYST (DOC) 8 - DIESEL PARTICULATE FILTER (DPF)
2. Position DOC onto the turbocharger. Install clamp finger tight.
3. Using new gaskets position NAC (6) onto the DOC (4) and Diesel Particulate Filter (DPF).
4. Install DOC to NAC and NAC to PDF flange nuts. Tighten nuts to 54 N.m (40 ft. lbs.).
5. Install differential pressure tube support nut (1). Tighten nut to 5 N.m (44 in. lbs.).
6. Install flexible differential pressure tubing (2).
7. Tighten the catalytic converter to turbocharger clamp to 17 N.m (13 ft. lbs). Using a rubber mallet, hit the DOC to turbocharger clamp three times around the perimeter of the clamp and tighten the clamp to 17 N.m (13 ft. lbs).
8. 4X4 Vehicles - Install transmission crossmember. Refer to «CROSSMEMBER, Lower Control Arm , Installation»(ref-457829-S30643828682012030200000) and «CROSSMEMBER, Transmission , Installation»(ref-457829-S11579147072012030200000) .
9. 4X4 Vehicles - Install transfer case skid plate. Refer to «PLATE, Skid, Front , Installation»(ref-457829-S14162190652012030200000) and «PLATE, Skid, Transfer Case , Installation»(ref-457829-S13100768802012030200000) .
10. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed.
11. Lower the vehicle.

DIESEL OXIDATION CATALYST (DOC)

The Diesel Oxidation Catalyst (DOC) is a ceramic flow through substrate coated with a catalyst washcoat that is integral to the DOC assembly. The close coupled DOC treats engine exhaust gases by converting harmful carbon monoxide, unburned hydrocarbons and other compounds into water, carbon dioxide and heat.

Pick-up vehicles use a separate DOC assembly.

Cab-Chassis vehicles use a combination Diesel Oxidation Catalyst/Diesel Particulate Filter (DOC/DPF)

CLOSE COUPLED CATALYST (CCC)

The CCC is basically a diesel oxidation catalyst (DOC) that is mounted very close to the turbocharger exhaust outlet. It is a metallic flow through substrate coated with a catalyst washcoat that is essential to the integrated operation of the aftertreatment assembly. The close coupled DOC treats engine exhaust gases by converting harmful carbon monoxide, unburned hydrocarbons and other compounds into water, carbon dioxide and heat. The ability to create heat is an important part of the system regeneration process.

NOx ADSORBER CATALYST (NAC)

The NAC is located downstream of the CCC. Using the heat and exhaust constituents coming from the CCC, the NAC traps various oxides of nitrogen, and then converts those into Carbon Dioxide, Nitrogen (N2) and water via a regeneration process controlled by the engine's electronic control module (ECM). The NAC also plays a role in reducing non-methane hydrocarbons (NMHC) from the exhaust gas.

DIESEL PARTICULATE FILTER

The NAC is located downstream of the CCC. Using the heat and exhaust constituents coming from the CCC, the NAC traps various oxides of nitrogen, and then converts those into Carbon Dioxide, Nitrogen (N2) and water via a regeneration process controlled by the engine's electronic control module (ECM). The NAC also plays a role in reducing non-methane hydrocarbons (NMHC) from the exhaust gas. DIESEL PARTICULATE FILTER (DPF): The diesel particulate filter (DPF) is a wall-pass ceramic filter substrate coated with a catalyst washcoat. It is located just downstream of the NAC. Exhaust gases flow from the NAC into the catalyzed diesel particulate filter (DPF) which traps and accumulates particulate matter, and further treats the exhaust gases to reduce any remaining unburned hydrocarbons and other harmful compounds. The trapped particulate matter will be periodically removed from the DPF via a regeneration process controlled by the engine electronic control module (ECM).

EVIC Message Center - Message - Catalyst Full

The engine Electronic Control Module (ECM) monitors the soot load in the diesel particulate filter. Under normal operating conditions the diesel particulate filter is self-cleaning, where accumulated soot is converted to ash. Under light load operating conditions, the driver may be notified via the vehicle's Electronic Vehicle Information Center (EVIC) message center "CATALYST FULL: SEE OWNERS MAN" will be displayed on the overhead console of your vehicle if the exhaust particulate filter reaches 80% of its maximum storage capacity. Under conditions of exclusive short duration and low speed driving cycles, your Cummins engine and exhaust aftertreatment system may never reach the conditions required to remove the trapped PM. If this occurs, "Catalyst Full See Owner Manual" will be displayed on the overhead console in your vehicle. If this message is displayed you will hear one chime to assist in alerting you of this condition. Catalyst Stat::::::::::80% Catalyst Stat::::::::::80% will replace the message "Catalyst Full See Owner Manual" after it is displayed for one minute. The engine Powertrain Control Module (PCM) will continue to monitor the amount of particulate matter trapped in the particulate filter. This message indicates the percentage of the particulate filter capacity that has been used. By simply driving your vehicle at highway speeds for as little as 45 minutes you can remedy the condition in the particulate filter system and allow your Cummins engine and exhaust aftertreatment system to remove the trapped PM and restore the system to normal operating condition. Catalyst Stat:::::::::::80%, 90%, 99% Catalyst Stat:::::::::::80%, 90%, 99% If you are unable to drive your vehicle under these conditions for an extended period of time after the initial warning notification, the Engine PCM will continue to monitor the particulate filter and will display the progression of particulate filter usage (80, 90, 99%) on the EVIC message center. CATALYST FULL SERVICE REQD If the particulate filter reaches 99% of its capacity, the overhead console in your vehicle will chime twice and display the message CATALYST FULL SERVICE REQD. At this point the engine PCM will register a fault code, the instrument panel will display a MIL light and the engine PCM will derate the truck, reducing its horsepower and torque output. The PCM derates the engine in order to limit the likelihood of permanent damage to the aftertreatment system. If this condition is not corrected and a dealer service is not performed, extensive exhaust aftertreatment damage can occur. In order to correct this condition it will be necessary to have the truck serviced by your local authorized dealer.

Intervention Regeneration Strategy - EVIC Message Process Flow (Late Build) The Cummins diesel engine meets all EPA Heavy Duty Diesel Engine Emissions Standards, resulting in the lowest emitting diesel engine ever produced. NOTE: Depending on the build date of your vehicle or if the software has been updated, the EVIC may display the following messages. To achieve these emissions standards, your vehicle is equipped with a state-of-the-art engine and exhaust system. The engine and exhaust after-treatment system work together to achieve the EPA Heavy Duty Diesel Engine Emissions Standards. These systems are seamlessly integrated into your vehicle and managed by the Cummins Powertrain Control Module (PCM). The PCM manages engine combustion to allow the exhaust system catalyst to trap and burn Particulate Matter (PM) pollutants, with no input or interaction on your part. Additionally, the overhead console in your vehicle has the ability to alert you to additional maintenance required on your truck or engine. Refer to the following messages that may be displayed on your Electronic Vehicle Information Center (EVIC)

Exhaust System - Regeneration Required Now "Exhaust System - Regeneration Required Now" will be displayed on the overhead console of your vehicle if the exhaust particulate filter reaches 80% of its maximum storage capacity. Under conditions of exclusive short duration and low speed driving cycles, your Cummins diesel engine and exhaust aftertreatment system may never reach the conditions required to remove the trapped PM. If this occurs, "Exhaust System - Regeneration Required Now" will be displayed on the overhead console in your vehicle. If this message is displayed, you will hear one chime to assist in alerting you of this condition. By simply driving your vehicle at highway speeds for as little as 45 minutes, you can remedy the condition in the particulate filter system and allow your Cummins diesel engine and exhaust after-treatment system to remove the trapped PM and restore the system to normal operating condition. Exhaust Filter XX% Full Indicates that the Diesel Particulate Filter (DPF) is approaching full. Exhaust System - Regeneration in Process Indicates that the Diesel Particulate Filter (DPF) is selfcleaning. Maintain your current driving condition until regeneration is completed. Exhaust System - Regeneration Completed Indicates that the Diesel Particulate Filter (DPF) selfcleaning is completed. If this message is displayed, you will hear one chime to assist in alerting you of this condition. Service Required - See Dealer Now Regeneration has been disabled due to a system malfunction. At this point the engine PCM will register a fault code, the instrument panel will display a MIL light. IMMEDIATE SERVICE IS REQUIRED. See your authorized dealer as damage to the exhaust system could occur soon with continued operation. Exhaust Filter Full - Power Reduced See Dealer The PCM derates the engine in order to limit the likelihood of permanent damage to the after-treatment system. If this condition is not corrected and a dealer service is not performed, extensive exhaust after-treatment damage can occur. In order to correct this condition it will be necessary to have your vehicle serviced by your local authorized dealer. IMMEDIATE SERVICE IS REQUIRED. See your authorized dealer, as damage to the exhaust system could occur soon with continued operation.

STANDARD PROCEDURE - STATIONARY DESOOT

Note. Stationary DeSoot will not perform without a P1451 DTC. Updating the ECM will automatically clear the P1451 DTC from the ECM's memory. If the soot threshold is great enough where a Stationary DeSoot is required, it may be necessary to drive the vehicle so that the P1451 DTC will reset.

Note. When using Diagnostic Scan Tool software at release 9.05, the fuel minimum specification to run the test is 1/4 of a tank of fuel.

1. Fill the vehicle with three (3) gallons of Ultra Low Sulfur diesel fuel to perform the procedure. NOTE: In order for Stationary DeSoot to begin, the vehicle must be parked with the parking brake engaged, be at normal operating temperature, have no active DTC unrelated to DeSoot, and have at least three gallons of fuel. If any of these conditions are violated after Stationary DeSoot begins, or if the service brake or accelerator pedal is pressed, Stationary DeSoot will abort.
2. Position the vehicle on a NONFLAMMABLE surface such as concrete. WARNING: Exhaust temperatures will be extremely high. Do not perform this procedure on flammable surfaces such as asphalt, grass, etc. or adjacent to property that may be damaged by the exhaust gases, or in a location where individuals may be required to pass adjacent to the exhaust.
3. Apply the parking brake.
4. Position the shift lever in Park or Neutral.
5. Lower the spare tire down as far as possible. It is not necessary to remove the spare tire from the vehicle.
6. Mark an area 12 feet (3.66 meters) by 12 feet (3.66 meters) surrounding the exhaust outlet. The exhaust outlet should be six feet from the fore and aft ends of the marked off area. NOTE: Ensure that the "HOT EXHAUST" labels are facing outward.
7. Ensure that the hood remains closed during the stationary regeneration operation.
8. If not already performed, connect the Diagnostic Scan Tool to the vehicle.
9. Start the engine.
10. Power ON the Diagnostic Scan Tool.
11. Scroll to the ECM menu
12. Select Stationary DeSoot NOTE: During Stationary DeSoot, engine RPM will be elevated to 1,100 RPM. When the engine RPM returns to normal idle, the Stationary DeSoot has completed or aborted.
13. Initiate Stationary DeSoot. NOTE: Stationary DeSoot may take up to one hundred (100) minutes to complete. It is not necessary to monitor the stationary regeneration cycle the entire one hundred minutes. In addition, it is not necessary to leave the Diagnostic Scan Tool connected to the vehicle once the stationary regeneration has been initiated. Periodic monitoring of the cycle can be accomplished by monitoring the percent of completion through the EVIC or by connecting the Diagnostic Scan Tool and reviewing the percent of completion on the scan tool.
14. Stationary DeSoot will automatically abort once the cycle is complete. If Stationary DeSoot needs to be aborted prior to the end of the cycle, any of the following manual methods can be used: Turning the ignition OFF Depressing the brake pedal Moving the PRNDL from P/N to D/R
15. Once Stationary DeSoot is complete, remove the anti-theft device.
16. Position the spare tire back into its stowage position.

6.7L DIESEL - CAB CHASSIS

Scheme 26

1. Disconnect and isolate negative battery cables.
2. Raise and support vehicle.
3. If equipped, remove skid plates.
4. On 4X4 models, remove transmission crossmember. Refer to «CROSSMEMBER, Lower Control Arm , Removal»(ref-457829-S02998048772012030200000) and «CROSSMEMBER, Transmission , Removal»(ref-457829-S13491836922012030200000) .
5. Saturate bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
6. Remove flexible tubing from particulate filter pressure sensor tubing.
7. Loosen and remove particulate filter pressure sensor tubing from Diesel Oxidation Catalytic/Diesel Particulate Filter (DOC/DPF) at the ports (4).
8. Disconnect and remove front temperature sensors (2).
9. Remove the rear temperature sensor.
10. Remove NOx sensor.
11. Remove the isolators (3).
12. Remove the Selective Catalytic Reduction (SCR) Catalyst and the tail pipe assembly and move toward rear of vehicle.
13. Remove exhaust down pipe to DOC/DPF flange nuts (5).
14. Remove DOC/DPF from the down pipe (1).
15. Remove and discard flange gaskets.

6.7L DIESEL - P/U

1. Disconnect and isolate negative battery cables.
2. Raise and support vehicle.
3. Saturate bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
4. Disconnect flexible exhaust differential pressure sensor tubing (2).
5. Remove exhaust pressure differential sensor tubing from Diesel Particulate Filter (DPF) (1).
6. When equipped, remove skid plates.
7. On 4X4 models, remove transmission crossmember. Refer to «CROSSMEMBER, Lower Control Arm , Removal»(ref-457829-S02998048772012030200000) and «CROSSMEMBER, Transmission , Removal»(ref-457829-S13491836922012030200000) .
8. Remove Diesel Particulate Filter (DPF) to NOx Absorber Catalyst (NAC) flange nuts (7).
9. Remove NAC to Diesel Oxidation Catalyst (DOC) to NAC flange nuts (5). Discard gasket.
10. Remove NAC (7) from isolators.
11. Remove DOC to muffler band clamp.
12. Remove DOC from vehicle.

1. Position new exhaust flange gasket on exhaust down pipe (1) flange (6).
2. Mount the DOC/DPF input to the down pipe (1).
3. Install flange nuts (5). Hand tighten only.
4. Install the isolators (3).
5. Position new exhaust flange gasket on DOC/DPF output flange.
6. If equipped, install the extension pipe.
7. Install the Selective Catalytic Reduction (SCR) catalyst. Refer to «CATALYST, Selective Catalytic Reduction (SCR) , Installation»(ref-457794-S09388993092012030200000) .
8. Install flange nuts. Hand tighten only.
9. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed.
10. Tighten flange nuts to 54 N.m (40 ft. lbs.).
11. Install temperature sensors (2). Tighten to 30 N.m (22 ft. lbs.).
12. Install NOx sensor. Tighten to 50 N.m (37 ft. lbs.). NOTE: Make sure there is not a dip in the pressure differential tubing.
13. Install exhaust differential pressure tubing. Tighten to 30 N.m (22 ft. lbs.).
14. Install flexible exhaust differential pressure sensor tubing.
15. Connect electrical connectors.
16. On 4X4 models, install transmission crossmember. Refer to «CROSSMEMBER, Lower Control Arm , Installation»(ref-457829-S30643828682012030200000) and «CROSSMEMBER, Transmission , Installation»(ref-457829-S11579147072012030200000) .
17. If equipped, install skid plates.
18. Lower vehicle.
19. Connect negative battery cables.
20. Using a scan tool, perform RESET REGENERATIVE FILTER TIMERS function found under ENGINE MISC. FUNCTIONS.

Scheme 27

1. Position the catalytic converter onto the turbocharger with the clamp (1) facing down as shown in illustration. Install the clamp (1) finger tight. 1 - MOUNTING BOLT 2 - TEMPERATURE SENSOR 3 - DIESEL PARTICULATE FILTER 4 - REAR DIFFERENTIAL PRESSURE TUBE 5 - BAND CLAMP 6 - FRONT DIFFERENTIAL PRESSURE TUBE 7 - CATALYTIC CONVERTER TO DPF FLANGE
2. Position new exhaust flange gaskets on catalytic converter to DPF flange.
3. Install flange bolts. Hand tighten only.
4. Install muffler and tailpipe assembly.
5. Install new band clamp. Hand tighten only.
6. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed.
7. Tighten flange nuts to 54 N.m (40 ft. lbs.).
8. Tighten band clamp nuts to 52 N.m (40 ft. lbs.).
9. Install temperature sensor. Tighten to 29.8 N.m (22 ft. lbs.).
10. Install front and rear (6 and 4) exhaust differential pressure tubing. Tighten to 30 N.m (22 ft. lbs.).
11. Tighten the catalytic converter to turbocharger clamp to 17 N.m (13 ft. lbs.). Using a rubber mallet, hit the DOC to turbocharger clamp three times around the perimeter of the clamp and tighten the clamp to 17 N.m (13 ft. lbs.).
12. Install flexible exhaust differential pressure sensor tubing.
13. On 4X4 models, install transmission crossmember. Refer to «CROSSMEMBER, Lower Control Arm , Installation»(ref-457829-S30643828682012030200000) and «CROSSMEMBER, Transmission , Installation»(ref-457829-S11579147072012030200000) .
14. When equipped, install skid plates.
15. Reconnect negative battery cables.
16. Using a scan tool, perform RESET REGENERATIVE FILTER TIMERS function found under ENGINE MISC. FUNCTIONS.

Scheme 28

The Selective Catalytic Reduction (SCR) is a catalyst element made of low precious metals used in reducing nitrous oxide gases (NOx) to an element of nitrogen. By injecting a Diesel Exhaust Fluid (DEF) solution upstream of a catalyst. The DEF solution will vaporize and decompose to form ammonia and carbon dioxide. When the ammonia vapor is introduced to the NOx gas, it converts it to a harmless nitrogen and water by product

3.7L/4.7L/5.7L ENGINE EXHAUST

1. Assemble muffler assembly (3) and clamps loosely to permit proper alignment of all parts.
2. Hang the muffler assembly (3) to the isolators (1, 2 and 4).
3. Tighten the clamp nuts to 54 N.m (40 ft. lbs.) torque.
4. Install the tailpipe assembly. Refer to «TAILPIPE, Exhaust , Installation»(ref-457794-S22794608362012030200000) .
5. Insure isolators (1, 2, and 4) are fully seated on exhaust hangers.
6. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed.
7. Lower the vehicle.
8. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.

5.7L ENGINE DUAL EXHAUST

1. Pre-assemble muffler (2) and clamp (1) loosely to permit proper alignment of all parts.
2. Raise and support the vehicle.
3. Hang the dual outlet muffler (2) on the isolators (4).
4. Install muffler (2) on the exhaust pipe (3). Tighten to 54 N.m (40 ft. lbs.).
5. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed.

DIESEL

1. Install the muffler hanger rods into the isolators.
2. Install the muffler into the extension pipe.
3. Install the muffler into the tail pipe.
4. Install the exhaust clamps, align the exhaust system, and tighten the exhaust clamps to 54 N.m (40 ft. lbs.).
5. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed.
6. Insure isolators are fully seated on exhaust hangers.
7. Lower the vehicle.
8. Connect the battery negative cables.
9. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.

Scheme 29

1. Raise and support the vehicle.
2. Unplug the upstream and downstream oxygen sensors. Swap over the sensors as necessary.
3. Remove and discard the exhaust pipe to manifold bolts (1) and J-nuts (2).
4. Loosen the exhaust pipe to Y-pipe clamp and separate the two pipes.
5. Shift the rear exhaust pipe rearward.
6. Carefully remove the exhaust system Y-pipe.

Scheme 30

1. Raise and support the vehicle on a hoist.
2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
3. Remove the exhaust pipe-to-DOC/DPF flange nuts (2).
4. 4X4 Vehicles - Remove transfer case skid plate. Refer to «PLATE, Skid, Front , Removal»(ref-457829-S37099224772012030200000) and «PLATE, Skid, Transfer Case , Removal»(ref-457829-S06628527422012030200000) .
5. 4X4 Vehicles - Remove transmission crossmember. Refer to «CROSSMEMBER, Lower Control Arm , Removal»(ref-457829-S02998048772012030200000) and «CROSSMEMBER, Transmission , Removal»(ref-457829-S13491836922012030200000) .
6. Remove the exhaust pipe-to-turbocharger clamp (5) and discard.
7. Remove the transmission mounted exhaust pipe support (4).
8. Separate the exhaust pipe (3).
9. Remove exhaust pipe (3).

3.7L/4.7L/5.7L

1. Position the exhaust pipe (3) with proper clearance between the frame and underbody parts. A minimum clearance of 25 mm (1.0 in.) is required.
2. Position the exhaust pipe (3) to manifolds. Install the new bolts (1) and new J-nuts (2).
3. Hand tighten the nuts while making sure the flange is evenly positioned around the pipe.
4. Alternate tightening sequence to further ensure the flange stays even around the pipe. Tighten the nuts to 31 N.m (23 ft. lbs.).
5. Tighten the clamp nuts to 54 N.m (40 ft. lbs.) torque.
6. Lower the vehicle.
7. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Refer to «Diagnosis and Testing»(ref-457794-S14547775892012030200000) .

6.7L DIESEL

1. Position DOC onto the turbocharger with the clamp (1) facing down as shown in illustration. Install the clamp (1) finger tight. 1 - DOC/DPF 2 - NUTS 3 - EXHAUST PIPE - 4 - EXHAUST PIPE SUPPORT 5 - TURBOCHARGER CLAMP
2. Using a new flange gasket, position exhaust pipe (3) on DOC/DPF flange and turbocharger flange.
3. Install flange nuts (2). Tighten nuts (2) to 54 N.m (40 ft. lbs.).
4. Install transmission mounted exhaust pipe support (4). Tighten bolts to 43 N.m (32 ft. lbs.).
5. 4X4 Vehicles - Install transmission crossmember. Refer to «CROSSMEMBER, Lower Control Arm , Installation»(ref-457829-S30643828682012030200000) and «CROSSMEMBER, Transmission , Installation»(ref-457829-S11579147072012030200000) .
6. 4X4 Vehicles - Install transfer case skid plate. Refer to «PLATE, Skid, Front , Installation»(ref-457829-S14162190652012030200000) and «PLATE, Skid, Transfer Case , Installation»(ref-457829-S13100768802012030200000) .
7. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed.
8. Tighten the DOC to turbocharger clamp to 17 N.m (13 ft. lbs). Using a rubber mallet, hit the DOC to turbocharger clamp three times around the perimeter of the clamp and tighten the clamp to 17 N.m (13 ft. lbs).
9. Lower the vehicle.
10. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.

Scheme 31

The Exhaust Differential Pressure Sensor is remotely mounted on the transmission housing. Two pressure tubes measure pressure before and after the Diesel Particulate Filter (DPF)/Diesel Oxidation Catalyst (DOC). The sensor is critical for fail-safe of regeneration strategy, because it interprets high pressure drops as possible high soot loads.

Scheme 32

Scheme 33

1. Raise and support vehicle.
2. Disconnect electrical connector.
3. Disconnect hoses at pressure differential pressure sensor.
4. Remove mounting bolt and differential pressure sensor.
5. Remove mounting bolts (1). A - CAB CHASSIS 5 - REAR EXHAUST TEMP SENSOR CONNECTOR- CAB/CHASSIS B - P/U 6 - REAR EXHAUST TEMP SENSOR - CAB/CHASSIS 1 - REAR DIFFERENTIAL PRESSURE SENSOR TUBING - CAB/CHASSIS 7 - REAR PRESSURE DIFFERENTIAL TUBING - P/U 2 - FRONT DIFFERENTIAL PRESSURE SENSOR TUBING - CAB/CHASSIS 8 - MOUNTING BOLTS 3 - FRONT EXHAUST TEMP SENSOR CONNECTOR - CAB/CHASSIS 9 - DPF - P/U 4 - DOC/DPF - CAB/CHASSIS 10 - FRONT PRESSURE DIFFERENTIAL TUBING - P/U
6. Remove pressure differential pressure tubing.

1. Loosely assemble exhaust tailpipe (2) and clamp (2) to permit proper alignment of all parts.
2. Position the exhaust tailpipe (2) for proper clearance with the underbody parts.
3. Tighten all clamp nuts to 54 N.m (40 ft. lbs.) torque.
4. Hang the tailpipe (2) onto the isolator (1).
5. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed.
6. Lower the vehicle.
7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Refer to «Diagnosis and Testing»(ref-457794-S14547775892012030200000) .

Scheme 34

1. Pre-assemble tailpipe (2) and clamp (1) loosely to permit proper alignment of all parts.
2. Raise and support the vehicle.
3. Hang the driver side tailpipe assembly (1) on the isolator (2).
4. Install driver side tailpipe assembly (1) to the top left outlet of the muffler assembly (3).Tighten to 54 N.m (40 ft. lbs.).
5. Install passenger side tailpipe assembly (1) to the lower right outlet of the muffler assembly (3).Tighten to 54 N.m (40 ft. lbs.).
6. Loosely install tailpipe tips (1) to the tailpipe assembly (2). NOTE: DO NOT tighten tailpipe tips at this time.
7. Check the exhaust system components for any contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed.
8. One properly aligned, tighten the tailpipe tips (2) to 25 N.m (19 ft. lbs.).
9. Lower the vehicle.
10. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Refer to «Diagnosis and Testing»(ref-457794-S14547775892012030200000) .

6.7L DIESEL ENGINE

1. Install the tailpipe into the muffler.
2. Install the tailpipe hanger rods into the isolators
3. Install the exhaust clamp, align the exhaust system, and tighten the clamp 48 N.m (35 ft. lbs.) torque.
4. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed.
5. Lower the vehicle.
6. Connect the battery negative cables.
7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.