jtodt
Junior Member
- Joined
- Oct 2, 2011
- Posts
- 3
- Reaction score
- 2
- Location
- Missouri
- Ram Year
- 2011 Quad Cab 4x4 Sport - Mineral Grey
- Engine
- Hemi 5.7L
If there is anyone out there that is wanting to get rid of the restriction in the factory y-pipe and does not want to pay to have new pipe welded in or does not want to lose the factory look? I have the answer. I would not recommend you to attempt this if you are not mechanically inclined. You will need mechanical skills, welding skills and metal fabrication skills.
Tools needed: Plasma torch, oxy acetylene torch, mig or tig welder. I used ratchet wrenches to take the bolts and nuts loose, I think that boxed end wrenches or socket and ratchet would work as well. 14mm bolts and 15mm nuts are what you will be taking loose.
Cost of modification: $0 if you have all of the above.
Time to allow: It took me around 3.5 hours.
DO NOT attempt if you don't have the skills or tools necessary to complete the task.
Step 1: Either use a lift or jack stands to give you some clearance off the ground.
Step 2: Use some penetrating oil to lube the four bolts where the factory exhaust bolts up to the exhaust manifolds, the joint where the y-pipe goes into the 3" pipe to the muffler and the clamp nuts, the joint where the 3" pipe goes into the muffler and the clamp nut.
Step 3: If the exhaust is cool enough to touch, unplug the four sensors behind the cats, two on each side.
Step 4: Loosen the two clamps on the 3" pipe that goes to the muffler. Take a pry bar and push the muffler back so that it will release from the 3" pipe. Remove the 3" pipe from the truck.
Step 5: Remove the four bolts that mount the exhaust to the exhaust manifolds. Take the exhaust loose from the manifolds and remove from the truck.
Step 6: Once you have the exhaust in your hands it is easy to see the restriction and what you will need to remove. Look into the end where the collar is welded around the two pipes. You can immediately see the design flaw where the pipes are smashed together. Now you will need to assess the exterior of the pipe and where you will want to cut with the plasma torch. Once you have made the cut with the plasma torch use the oxy acetylene torch to finish the cuts where the plasma would not fit. Be careful not to hack the pipe up to bad. You can use the gas torch to get into the open end of the pipe to finish torching out the restriction.
Step 7: With the restriction removed you can begin to use the torch and a pry bar to form the steel around to where it will be tighter to weld. You can actually use the torch to heat the steel to open up the pipe where it is bent before the y. Heat it and use the pry bar to form the steel. Be careful not to melt the pipe.
Step 8: Now weld the joints solid and reinstall the exhaust.
I immediately noticed the that the exhaust was throatier and the throttle response was more responsive. I am not one to waste my gas or rubber, but before my truck would not spin the tires form a dead stop it might chirp them a little. Now it will spin the tires when you floor it. I had no idea that the OEM exhaust was so restrictive until I modified mine, WOW. Now all there is to do is finish it off with a Magna Flow cat back system.
I did not take that many pics as I was doing this. You can see the before and after from the end of the pipe. You can really see how much it opened it up.
Tools needed: Plasma torch, oxy acetylene torch, mig or tig welder. I used ratchet wrenches to take the bolts and nuts loose, I think that boxed end wrenches or socket and ratchet would work as well. 14mm bolts and 15mm nuts are what you will be taking loose.
Cost of modification: $0 if you have all of the above.
Time to allow: It took me around 3.5 hours.
DO NOT attempt if you don't have the skills or tools necessary to complete the task.
Step 1: Either use a lift or jack stands to give you some clearance off the ground.
Step 2: Use some penetrating oil to lube the four bolts where the factory exhaust bolts up to the exhaust manifolds, the joint where the y-pipe goes into the 3" pipe to the muffler and the clamp nuts, the joint where the 3" pipe goes into the muffler and the clamp nut.
Step 3: If the exhaust is cool enough to touch, unplug the four sensors behind the cats, two on each side.
Step 4: Loosen the two clamps on the 3" pipe that goes to the muffler. Take a pry bar and push the muffler back so that it will release from the 3" pipe. Remove the 3" pipe from the truck.
Step 5: Remove the four bolts that mount the exhaust to the exhaust manifolds. Take the exhaust loose from the manifolds and remove from the truck.
Step 6: Once you have the exhaust in your hands it is easy to see the restriction and what you will need to remove. Look into the end where the collar is welded around the two pipes. You can immediately see the design flaw where the pipes are smashed together. Now you will need to assess the exterior of the pipe and where you will want to cut with the plasma torch. Once you have made the cut with the plasma torch use the oxy acetylene torch to finish the cuts where the plasma would not fit. Be careful not to hack the pipe up to bad. You can use the gas torch to get into the open end of the pipe to finish torching out the restriction.
Step 7: With the restriction removed you can begin to use the torch and a pry bar to form the steel around to where it will be tighter to weld. You can actually use the torch to heat the steel to open up the pipe where it is bent before the y. Heat it and use the pry bar to form the steel. Be careful not to melt the pipe.
Step 8: Now weld the joints solid and reinstall the exhaust.
I immediately noticed the that the exhaust was throatier and the throttle response was more responsive. I am not one to waste my gas or rubber, but before my truck would not spin the tires form a dead stop it might chirp them a little. Now it will spin the tires when you floor it. I had no idea that the OEM exhaust was so restrictive until I modified mine, WOW. Now all there is to do is finish it off with a Magna Flow cat back system.
I did not take that many pics as I was doing this. You can see the before and after from the end of the pipe. You can really see how much it opened it up.
