Dodge Durango 2004-2009 Exhaust Specifications
Explore detailed exhaust system specifications for the 2004-2009 Dodge Durango, including part numbers, dimensions, and compatibility. Ideal for maintenance, repair, and performance upgrades.
Overview Specifications
This document provides detailed specifications and information about the exhaust system for the 2004-2009 Dodge Durango. It is designed to help users understand the components, configurations, and technical details of the exhaust system. Use this guide to locate specific information, compare specifications, or troubleshoot issues. The document is organized into sections for easy navigation and includes a quick reference table for key specifications.
How to Use
Use the search functionality to find specific terms or components within the document. Enter keywords like 'catalytic converter' or 'muffler' to quickly locate relevant sections.
Navigate through the document using the section titles and subsections. Each major section is divided into detailed subsections, making it easy to find specific information about the exhaust system.
Key Specifications
Exhaust Pipe Diameter
2.5 inches
Catalytic Converter Type
Ceramic substrate
Muffler Material
Aluminized steel
Exhaust System Weight
45-55 lbs
Warranty Coverage
5 years/60,000 miles
Available Specifications
Exhaust System Components
This section covers the primary components of the exhaust system, including the exhaust manifold, catalytic converter, muffler, and tailpipe. Learn about the materials, design, and function of each component.
Exhaust System Components
This section covers the primary components of the exhaust system, including the exhaust manifold, catalytic converter, muffler, and tailpipe. Learn about the materials, design, and function of each component.
Exhaust Manifold
- Made of cast iron or stainless steel
- Directs exhaust gases from the engine cylinders
- Designed to withstand high temperatures
- Bolted directly to the engine block
Catalytic Converter
- Reduces harmful emissions
- Contains a ceramic or metallic catalyst
- Located between the exhaust manifold and muffler
- Requires periodic inspection for clogging
Muffler
- Reduces exhaust noise
- Constructed from aluminized steel
- Includes internal baffles for sound dampening
- Mounted under the vehicle's rear section
Exhaust System Configurations
This section explains the different exhaust system configurations available for the 2004-2009 Dodge Durango, including single and dual exhaust setups. Understand the benefits and differences between these configurations.
Exhaust System Configurations
This section explains the different exhaust system configurations available for the 2004-2009 Dodge Durango, including single and dual exhaust setups. Understand the benefits and differences between these configurations.
Single Exhaust System
- Standard configuration for most models
- Uses one exhaust pipe and muffler
- Simpler design and lower cost
- Adequate for most driving conditions
Dual Exhaust System
- Available on higher-performance models
- Uses two exhaust pipes and mufflers
- Improves engine performance and sound
- Requires more space and maintenance
Maintenance and Troubleshooting
This section provides guidance on maintaining the exhaust system and troubleshooting common issues. Learn how to inspect, clean, and replace components to ensure optimal performance.
Maintenance and Troubleshooting
This section provides guidance on maintaining the exhaust system and troubleshooting common issues. Learn how to inspect, clean, and replace components to ensure optimal performance.
Routine Maintenance
- Inspect for rust and corrosion
- Check for loose or damaged hangers
- Listen for unusual noises or leaks
- Replace worn gaskets and seals
Common Issues
- Excessive noise due to muffler damage
- Reduced performance from clogged catalytic converter
- Rust and corrosion in harsh climates
- Leaks at connection points
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Component Specifications
Overview
- Type
- Dual exhaust system
- Configuration
- Rear exit
- Platform
- 2004-2009 Dodge Durango
- Material
- Stainless steel
- Location
- Underbody, rear
Dimensions
- Pipe Diameter
- 2.5 inches (63.5 mm)
- Tailpipe Length
- 18 inches (457.2 mm)
- Muffler Length
- 24 inches (609.6 mm)
- Muffler Width
- 8 inches (203.2 mm)
- Muffler Height
- 6 inches (152.4 mm)
- Catalytic Converter Length
- 14 inches (355.6 mm)
- Catalytic Converter Diameter
- 5 inches (127 mm)
Materials
- Exhaust Pipes
- 409 stainless steel
- Muffler
- Aluminized steel
- Catalytic Converter
- Ceramic substrate with stainless steel shell
- Tailpipe
- 304 stainless steel
Features
- Performance
-
- Reduced backpressure
- Enhanced exhaust flow
- Improved horsepower
- Better fuel efficiency
- Durability
-
- Corrosion-resistant materials
- Heat-resistant coatings
- Reinforced welds
- Impact-resistant design
- Sound
-
- Tuned muffler for optimal sound
- Reduced cabin noise
- Aggressive exhaust tone
- Minimized drone
- installation
-
- Direct bolt-on design
- Pre-fabricated hangers
- Alignment brackets
- Compatible with OEM mounts
- Emissions
-
- EPA-compliant catalytic converter
- Low emissions output
- O2 sensor compatibility
- Efficient exhaust gas recirculation
Safety Features
- Heat Management
-
- Heat shields for underbody protection
- Thermal insulation on critical components
- Structural integrity
-
- Reinforced hangers
- Crush-resistant pipes
- Emissions Control
-
- Catalytic converter with O2 sensor
- Leak-proof gaskets
Comfort Features
- Noise Reduction
-
- Tuned muffler design
- Sound-dampening materials
- Vibration Control
-
- Flexible exhaust hangers
- Rubber isolators
- Heat Management
-
- Underbody heat shields
- Thermal wrap on pipes
Accessories
- Performance Upgrades
-
- High-flow catalytic converter
- Performance muffler
- Exhaust tips
- Maintenance Tools
-
- Exhaust hanger removal tool
- Gasket set
- Clamp kit
- Protective Gear
-
- Heat-resistant gloves
- Exhaust wrap
- Underbody coating
Maintenance
- Service interval
- Every 30,000 miles or 24 months
- Service Items
-
- Inspect for leaks
- Check hangers and mounts
- Clean exhaust tips
- Inspect catalytic converter
- Test O2 sensors
- Maintenance Notes
- Regularly check for rust or corrosion, especially in winter climates.
Warranty
- Parts Warranty
- Miles: 60,000Years: 5Coverage: Manufacturer defects
- Labor Warranty
- Miles: 30,000Years: 2Coverage: Installation errors
- Corrosion Warranty
- Miles: UnlimitedYears: 10Coverage: Rust-through protection
- Performance Warranty
- Miles: 50,000Years: 3Coverage: Guaranteed exhaust flow
Production Details
- Manufacturer
- MagnaFlow
- Manufacturing Process
-
- Laser cutting
- Robotic welding
- Pressure testing
- Quality inspection
- Quality Control
- Leak Test: 100% tested for leaksMaterial inspection: X-ray and ultrasonic testingFitment Check: OEM compatibility verification
- Sustainability Practices
-
- Recycled materials used
- Low-emission manufacturing
- Waste reduction initiatives
- Production Metrics
- Annual Output: 500,000 unitsDefect Rate: Less than 0.1%Lead Time: 2-4 weeks
Service Information for exhaust Service
Maintenance and service requirements specific to this component
- Inspect exhaust system for leaks
- Check hangers and mounts for wear
- Clean exhaust tips
- Inspect catalytic converter for damage
- Test O2 sensor functionality
Ensure all connections are tight and free of corrosion.
- Replace exhaust gaskets
- Inspect and replace hangers if necessary
- Check for rust or corrosion
- Test exhaust backpressure
- Inspect heat shields
Use OEM or equivalent parts for replacements.
- Replace catalytic converter if needed
- Inspect and replace muffler if damaged
- Check entire exhaust system alignment
- Perform emissions test
- Replace O2 sensors if faulty
Major service may require professional tools and equipment.
Frequently Asked Questions
Find answers to common questions about torque specifications
Q1 Is this exhaust system compatible with all 2004-2009 Dodge Durango models?
Is this exhaust system compatible with all 2004-2009 Dodge Durango models?
This exhaust system is designed to be compatible with all 2004-2009 Dodge Durango models, including both V6 and V8 engine configurations. It is engineered to meet OEM specifications, ensuring proper fitment and performance. However, it is recommended to verify your vehicle's specific trim and engine type before purchase to ensure compatibility. Some aftermarket modifications may require additional adjustments for proper installation.
Q2 What maintenance is required for the exhaust system?
What maintenance is required for the exhaust system?
Regular maintenance for the exhaust system includes inspecting for rust, cracks, or leaks, especially around joints and hangers. Cleaning the exterior with a mild detergent can prevent corrosion. Ensure all bolts and clamps are tightened to the manufacturer's specifications. It is also advisable to check the system after driving in harsh conditions, such as salted roads, to maintain optimal performance and longevity.
Q3 How do I install or replace the exhaust system on a 2004-2009 Dodge Durango?
How do I install or replace the exhaust system on a 2004-2009 Dodge Durango?
To install or replace the exhaust system, first, lift the vehicle securely using a jack and stands. Remove the old exhaust by loosening clamps and bolts, starting from the rear and working forward. Install the new system by aligning components and securing them with provided hardware. Ensure proper alignment and clearance from the undercarriage. Tighten all connections to the specified torque and check for leaks before lowering the vehicle.
Q4 What should I do if my exhaust system is making unusual noises?
What should I do if my exhaust system is making unusual noises?
Unusual noises from the exhaust system, such as rattling or hissing, often indicate loose components, leaks, or damaged parts. Inspect the system for loose clamps, broken hangers, or holes in the piping. Tighten or replace any faulty parts as needed. If the issue persists, consult a professional mechanic to diagnose and resolve the problem, as it could affect vehicle performance and emissions.
Q5 How can I optimize the performance of my exhaust system?
How can I optimize the performance of my exhaust system?
To optimize performance, consider upgrading to a high-flow catalytic converter or performance muffler for improved exhaust flow. Regularly inspect and clean the system to prevent blockages. Ensure proper alignment and secure mounting to reduce vibrations. Additionally, pairing the exhaust system with a compatible air intake can enhance overall engine efficiency and power output.
Factory Service Resources
Access official service manuals, technical documents, and repair guides. These resources provide detailed procedures, specifications, and diagrams directly from the manufacturer.
2004-2009 Dodge Durango Service Manual
Coming SoonComprehensive guide covering maintenance, repair, and technical specifications for the 2004-2009 Dodge Durango.
Technical Service Bulletin: Exhaust System Updates
Coming SoonDetails updates and fixes for common exhaust system issues in 2004-2009 Dodge Durango models.
Dodge Durango Exhaust Parts Catalog
Coming SoonCatalog listing OEM and aftermarket exhaust components for 2004-2009 Dodge Durango models.
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Technical Information
- All specifications, including torque values, fluid capacities, and maintenance procedures, should be verified against your vehicle's factory service manual.
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