Hemi owners, take note: This flaw could be hiding under your hood.
A cracked exhaust manifold might not show up until your next cold morning start. But when it does, it could result in hundreds or even thousands of dollars in repair costs. A viral mechanic video is offering both a warning and a fix.
A viral TikTok clip from Dave’s Auto Center (@davesengines) in Centerville, Utah, shows viewers up close how the stock manifold on a Dodge Ram or other Hemi engine-equipped vehicles could fail.
“There’s like a put-put-put-put noise, and it happens almost on every Hemi,” the unnamed mechanic tells us. “These manifolds are really thin, and it’s just a poor design, and so they flex. Then, that flexing leads to cracking.”
Why These Manifolds Crack
Ram trucks powered by Hemi V‑8 engines, including the 5.7L and 6.4L variants, are seeing an uptick in exhaust manifold failures.
This design vulnerability isn’t new. Enthusiasts on DIY forums have flagged the problem for years, often noting broken bolts, warped manifolds, or part shortages. An official Stellantis Technical Service Bulletin from 2022 acknowledges that for 2019-2021 Ram 1500 trucks with the 5.7L Hemi, drivers may hear a persistent “ticking” noise on cold starts. That’s a symptom linked to exhaust manifold cracks.
The bulletin instructs dealers to inspect for cracked manifolds and, if found, replace the entire manifold assembly, including bolts, gaskets, shields, and tie bars, all as part of a covered warranty repair.
Industry experts have also traced the root causes to combative heat cycles. The cast‑iron manifold and steel bolts expand and contract at different rates, especially during thermal cycling. In newer Ram models, a reinforcing metal bar spanning the bolts has reportedly shifted stress from the bolts to the manifold casting, leading to cracked manifolds instead of broken bolts.
Popular automotive outlet MotorBiscuit concurs that while earlier models suffered bolt failures, newer generation trucks see more manifold cracking, a shift likely tied to updated hardware designs.
The telltale symptom is a cold-start ticking, audible near the manifold area, which typically fades as the engine warms. This is explicitly referenced in the Stellantis bulletin.
Symptoms can extend beyond noise:
Reduced engine performance and potential check engine light activation, as exhaust leaks can skew oxygen sensor readings.
Increased heat and noise in the cabin area due to escaping exhaust gases.
Potential safety risks from exhaust gases entering the passenger compartment—though rare, these make prompt diagnosis wise.
OEM Replacements and Aftermarket Upgrades
Stellantis recommends replacement using a full exhaust manifold kit, which includes improved fasteners and tie bars, as part of the regular warranty coverage if the issue is detected within the specified limits.
Cost-wise, dealership parts and labor for replacing both sides average around four hours of shop time, per the bulletin, though labor costs vary regionally.
Aftermarket solutions like BD Diesel’s manifold kit offer key upgrades that address failure points:
Constructed from high-silicon ductile iron, which better resists warping.
Includes longer fasteners with spacers and independent heat shield mounting points to reduce stress.
Comprehensive kit includes all necessary gaskets and hardware.
While precise pricing from automotive outlets is limited, some retailers list BD kits around the $515-$532 range.
While headers, both shorty and long-tube, are promoted for performance and heat management, they come at a higher cost, often around $1,000+, and have mixed long-term reliability, particularly at welds.
What Ram Owners Should Do Next
Cracked exhaust manifolds may sound like a nuisance, but the implications go beyond noise. Left unchecked, leaks can reduce engine performance, trigger check-engine lights, and even allow exhaust gases to seep into the cabin. Stellantis has issued technical service guidance acknowledging the problem with late-model Ram 1500s equipped with the 5.7L Hemi, underscoring that the issue is linked to a design flaw with real-world consequences.
Owners weighing their options should consider warranty coverage, aftermarket upgrades, and preventive checks to avoid bigger bills down the road.
Catch it early. If your Ram with a Hemi cranks over cold and you hear that distinct ticking, especially shortly after sitting, it’s time for inspection.
Take advantage of warranty coverage. If your 1500 is a 2019-2021 model, show service personnel the Stellantis bulletin to ensure proper diagnosis and covered repair.
Consider a long-term fix. The OEM repair addresses the crack but may not prevent future failures. An aftermarket kit like BD Diesel’s adds durability improvements.
Know your options. OEM repairs, though more expensive, carry warranty support. Aftermarket parts offer a stronger design. Header systems offer performance benefits but come with complexity and higher cost.
Motor1 reached out to the creator via phone and email.
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