Hemi Exhaust Manifold New Design?

[Wild one]

It's getting better - the air expedited gaskets don't fit either. Rem Flex 6022 does NOT fit 6.4L BGE Hemi in Ram 2500 trucks. Hole pattern totally different. WTF

You need a better shop,the 6022's fit perfectly fine on the (3) 6.4's i've put headers on,and the 6.4 car manifolds fit perfectly on a 5.7.The bolt patterns didn't change between the 6.4 and 5.7.The only thing i could see might be the hole for the egr on the truck 6.4's,but any decent shop should be able to drill a matching hole in the gaskets if they don't have the hole

 

[HEMIMANN]

You need a better shop,the 6022's fit perfectly fine on the (3) 6.4's i've put headers on,and the 6.4 car manifolds fit perfectly on a 5.7.The bolt patterns didn't change between the 6.4 and 5.7.The only thing i could see might be the hole for the egr on the truck 6.4's,but any decent shop should be able to drill a matching hole in the gaskets if they don't have the hole

I wasn't able to break in and do personal inspections with my and the shop's schedule. I've used this shop for 15 years. they've never failed me and also said they've done a number of HD Rams. Don't know if that means the 5.7 or 6.4 or both.

The EGR is a cast and machined boss, I saw that on the manifold itself so know why that wouldn't work without a complete blockoff and re-tune.

At this point I'm just royally pissed off, frustrated and tired. I've run around most of the day getting and returning parts. I don't know what's different between the cars and the trucks, and frankly, I shouldn't have to - this stuff is not that difficult.

 

[emjohn4]

I'm late to the replies, but...it isn't / wasn't that difficult to sand down the manifolds. I actually replaced my manifolds with shorty headers, and a year later replaced the shorty headers with the OEM manifolds (after sanding them flat). I used a belt sander from ebay / amazon / harbor freight; hooked up a shop vac, and just moved them fore & aft on the belt for about an hour each, and that was it.

I used Mopar gaskets, and this repair has been good for about 40k miles so far. The truck had ~70k miles when the factory bolts broke.

I'd do it again.

 

[HEMIMANN]

I'm late to the replies, but...it isn't / wasn't that difficult to sand down the manifolds. I actually replaced my manifolds with shorty headers, and a year later replaced the shorty headers with the OEM manifolds (after sanding them flat). I used a belt sander from ebay / amazon / harbor freight; hooked up a shop vac, and just moved them fore & aft on the belt for about an hour each, and that was it.

I used Mopar gaskets, and this repair has been good for about 40k miles so far. The truck had ~70k miles when the factory bolts broke.

I'd do it again.
View attachment 558838

Yep - that's no longer the long pole in the water for me. It took me a bit to learn there were NO aftermarket manifolds for the 6.4 truck engine, nor gaskets.

I ranted not just to vent but hopefully save others from having to learn the hard way.
The stock manifolds have been resurfaced, I bought Dorman stainless hardware, MOPAR gaskets were in stock in the metro region. Repair will be completed next week.

 

[crackerjack1957]

Ram 2500 6.4L Upgrade Part 24 hemi exhaust manifold install.

In this video we install the exhaust manifolds to the cyl heads and review the bolt options that we went with.â–º Ram 2500 6.4L Playlist:https://www.youtube.co...

youtu.be

 

[HEMIMANN]

When you consider 70%-80% of heavy duty trucks sell with Cummins engines, and peak sales were around 100,000 Cummins engines a year, that means 33,000 6.4L Hemi engines ain't a lot to pay attention to, if at all.

Frankly, I'm surprised they even bothered with a larger displacement V8 engine. But I guess it wasn't a huge departure from the 5.7L to the 6.4L to get those extra 33,000 sales a year.

They sure orphaned it in a number of ways compared to the 5.7L engine, though.

 

[HEMIMANN]

Ram 2500 6.4L Upgrade Part 24 hemi exhaust manifold install.

In this video we install the exhaust manifolds to the cyl heads and review the bolt options that we went with.â–º Ram 2500 6.4L Playlist:https://www.youtube.co...

youtu.be

Yeah, it's pretty basic, right? A head, a gasket, a manifold, and some fasteners. And a heat shield.

I don't get why there are so many part variations, much less guaranteed clamping failure from the factory. This should be simple. To find out there was with and without EGR tap boss manifolds that changed over time on some models and not on others was mind-blowing to me.

 

[Sherman Bird]

After literally running around for hours and days, here is what I found -

For the 6.4L Hemi (BGE) Ram Truck Engine:

NO aftermarket exhaust manifolds exist - none, zero, zilch, nada - not in plain manifolds or shorty headers. The ONLY aftermarket manifold is a full ARH long tube stainless exist system for $2,000 just for the parts, add labor and re-tuning to the bill. No thank you. The only option is to sand down your stock bosses flat, or order new stock you'll have to sand down again later anyway.

NO aftermarket exhaust gaskets exist - not Remflex or FelPro or anybody else. NONE. Had to order a new set of MOPAR gaskets.

ARH does NOT make aftermarket manifold hardware for this engine. The ONLY choices are MOPAR or Dorman. I went with Dorman because they have optional stainless and drylock patches.

What a crock of $hit for something that should never fail from the factory in the first place. All sorts of incorrect catalogues with misinformation out there.

I wonder if it is also incompetence, rather than just a catalog issue. I remember when parts people used a long row of catalogs on the counter top. Computer? Maybe those the size of small buildings in cold corporate rooms. But not so prolifically as today. I deal every day with incompetent and inexperienced young'uns who are ONLY capable of looking up a part on a computer screen. They have no "moxie" when it comes time to use their head for something besides a hat-rack. The old geezers that I've known through the decades have retired, quit, or died. These were the guys who "knew" the off the wall/ not published details which came in so handy.

I remember old man Stephens, who was the parts manager at Pontiac, in our neighborhood. I had to go buy a new driveshaft for my grandfather's 1979 Parisienne, which, due to it's aluminum construction in about 1982, unwrapped itself. He looked it up, wrote down the 2 possible part numbers it could be, told me he had one of them, and picked up the phone and located the other one at another nearby dealer. He then instructed me to get the stamping number off the axle tube, where I could find it, and showed me which stamping number correlated with which driveshaft part number. Now, THAT'S service!! These youngsters now simply don't give a $hit about customer satisfaction.

 

[HEMIMANN]

I wonder if it is also incompetence, rather than just a catalog issue. I remember when parts people used a long row of catalogs on the counter top. Computer? Maybe those the size of small buildings in cold corporate rooms. But not so prolifically as today. I deal every day with incompetent and inexperienced young'uns who are ONLY capable of looking up a part on a computer screen. They have no "moxie" when it comes time to use their head for something besides a hat-rack. The old geezers that I've known through the decades have retired, quit, or died. These were the guys who "knew" the off the wall/ not published details which came in so handy.

I remember old man Stephens, who was the parts manager at Pontiac, in our neighborhood. I had to go buy a new driveshaft for my grandfather's 1979 Parisienne, which, due to it's aluminum construction in about 1982, unwrapped itself. He looked it up, wrote down the 2 possible part numbers it could be, told me he had one of them, and picked up the phone and located the other one at another nearby dealer. He then instructed me to get the stamping number off the axle tube, where I could find it, and showed me which stamping number correlated with which driveshaft part number. Now, THAT'S service!! These youngsters now simply don't give a $hit about customer satisfaction.

Oh, man do I ever remember those big books on the row rack at the counter. We also looked at JC Whitney Catalog a lot - Chicago based.

 

[EdGs]

I wonder if it is also incompetence, rather than just a catalog issue. I remember when parts people used a long row of catalogs on the counter top. Computer? Maybe those the size of small buildings in cold corporate rooms. But not so prolifically as today. I deal every day with incompetent and inexperienced young'uns who are ONLY capable of looking up a part on a computer screen. They have no "moxie" when it comes time to use their head for something besides a hat-rack. The old geezers that I've known through the decades have retired, quit, or died. These were the guys who "knew" the off the wall/ not published details which came in so handy.

I remember old man Stephens, who was the parts manager at Pontiac, in our neighborhood. I had to go buy a new driveshaft for my grandfather's 1979 Parisienne, which, due to it's aluminum construction in about 1982, unwrapped itself. He looked it up, wrote down the 2 possible part numbers it could be, told me he had one of them, and picked up the phone and located the other one at another nearby dealer. He then instructed me to get the stamping number off the axle tube, where I could find it, and showed me which stamping number correlated with which driveshaft part number. Now, THAT'S service!! These youngsters now simply don't give a $hit about customer satisfaction.

I still have some old paper books for certain parts we use.

It is simply easier gor me to look it up than to try and navigate a website that isn't user-friendly, and there are no shortage of those.

 

[emjohn4]

I'm not that old...but I have some new grads working for me...who look at me like I'm nuts for printing out documents to read / edit / comment on.

Oh well, trees are a renewable resource. That usually gets a death glare to which I smile back at.

 

[Sherman Bird]

I'm not that old...but I have some new grads working for me...who look at me like I'm nuts for printing out documents to read / edit / comment on.

Oh well, trees are a renewable resource. That usually gets a death glare to which I smile back at.

I'm willing to bet that it isn't so much a "Death Glare"! No, it is a "how dare you to expect me to function/think/do/exert effort!?".
My late father, who was HIGHLY educated, got red-faced, neck vein-popping furious at us kids when we would be mentally lazy or wantonly stupid. He spent a fortune on encyclopedias, National Geographic, and other forms of educational support for us kids. He would tutor us when we had problems with our school work.... but, bring home a low grade without having ASKED him for help? WHOOO!!!

 

[HEMIMANN]

Starting the day with the truck still up in the air on the hoist. Hopefully the manifolds come back from the machine shop soon, now that I have correct hardware and gaskets!

 

[HEMIMANN]

The manifolds are finished, the rep said they were "very warped" and took quite a while to flatten. I didn't get a number out of him.

At any rate, I'm on a valid repair path now. I think.

 

[EdGs]

The manifolds are finished, the rep said they were "very warped" and took quite a while to flatten. I didn't get a number out of him.

At any rate, I'm on a valid repair path now. I think.

Good news, @HEMIMANN, glad you are having good progress.

My manifolds were warped at the rear cylinders, and twisted a bit too.

Have even heard of some where both ends warp.

Some even warp so much that they don't seal up even when warm.

After it's fixed, you will notice every other Ram that has broken bolts, such a distinct sound.

 

[HEMIMANN]

It's fixed.

The manifolds must've really been warped, cause it sat outside last night and when I went to pick it up it was -5 degrees F cold-soaked, and it was quiet when I started it. Majorly quiet compared to what it was.

It was quiet all the way home. I hadn't noticed it gradually getting louder and louder over the years. 8 years old, 61,000 miles, extreme temperature thermal cycling in the American Siberia.

 

[EdGs]

It's fixed.

The manifolds must've really been warped, cause it sat outside last night and when I went to pick it up it was -5 degrees F cold-soaked, and it was quiet when I started it. Majorly quiet compared to what it was.

It was quiet all the way home. I hadn't noticed it gradually getting louder and louder over the years. 8 years old, 61,000 miles, extreme temperature thermal cycling in the American Siberia.

That's awesome, @HEMIMANN. Glad you got it done.

 

[Wild one]

It's fixed.

The manifolds must've really been warped, cause it sat outside last night and when I went to pick it up it was -5 degrees F cold-soaked, and it was quiet when I started it. Majorly quiet compared to what it was.

It was quiet all the way home. I hadn't noticed it gradually getting louder and louder over the years. 8 years old, 61,000 miles, extreme temperature thermal cycling in the American Siberia.

Mothers lock up your Daughters,Brians back on the road

 

[HEMIMANN]

Mothers lock up your Daughters,Brians back on the road

Nuh-uh....they can't hear me sneak up now.
This be a 6.4, not a 5.7 rattler

 

[EdGs]

I'll bet you are relieved it's finally fixed. You sure had a good bit of craziness with the back-and-forth you went through.

Stressful.