BD Diesel • 6.7L Cummins

6.7L Cummins Exhaust Manifold Upgrades: Pickups vs. Cab & Chassis

Why factory manifolds crack and leak on Ram HD trucks—and how BD’s thick-wall, slip-joint, pulse-divided manifolds restore spool, reduce drive pressure, and stay sealed under DPF regen heat.

Quick Summary: Stock 6.7L manifolds suffer from thermal warp and flange/stud stress, especially with DPF regens and towing. BD’s high-silicon ductile iron, thick-wall, slip-joint, pulse-divided manifolds are fully EGR-compatible, include all gaskets/grade 10.9 hardware, ship pre-drilled for a pyrometer, and carry a 36-month/75,000-mile parts warranty. Choose the Pickup kit for 2500/3500, or the dedicated Cab & Chassis kit for 3500/4500/5500 upfits.

Ask any Ram owner who tows in the hills and you’ll hear the same story: the factory 6.7L exhaust manifolds run hot, especially during regeneration. Over time, thin castings and short hardware see-saw with heat cycles, warping flanges and stressing studs until the tell-tale tick and sooty leaks appear. Power feels mushy off-boost, EGTs climb sooner, and turbo response dulls. That’s the problem BD set out to solve with a manifold that expands without fighting itself, keeps ports sealed, and feeds the turbine with clean, even pulses.

What BD Changes (and Why It Matters)

  • High-silicon ductile iron casting: Handles the brutal temp swing of DPF regens without micro-cracking or creep.
  • Thick-wall runners & flanges: More mass = slower heat saturation and less flange distortion.
  • Precision slip joint: Lets the manifold grow and shrink with heat so clamp load stays on the gasket—not the stud.
  • Pulse-divided design: Cleaner energy to the turbine for quicker spool and lower drive pressure under load.
  • Fully EGR-compatible: Keeps factory emissions strategy intact—no tuning required.
  • Pre-drilled pyrometer port: Add an EGT probe and watch temps on long grades.
  • Complete install kit: EGR, exhaust port, and turbo gaskets plus grade 10.9 black-oxide bolts and spacers.

Pickup Manifold Kit — Ram 2500/3500

Built for standard pickup chassis packaging and downpipe geometry.

  • Shop: BD 6.7L Cummins Pickup Manifold Kit
  • Material/Design: High-Si ductile iron, thick-wall, pulse-divided, slip-joint
  • Includes: EGR/turbo/exhaust gaskets, grade 10.9 bolts & spacers, pyrometer port
  • Warranty: 36 months / 75,000 miles
  • Install time: ~8 h 41 m
  • SEMA Cert: SC-BDD01-0155
  • Note: Not for sale on licensed California vehicles
  • Replaces Chrysler # 68027070AA/AB, 68210184AB • Cummins # 5301441

Cab & Chassis Manifold — Ram 3500/4500/5500

For upfit rigs that idle, PTO, and live heavy—optimized for C&C packaging and heat load.

  • Shop: BD 6.7L Cummins Cab & Chassis Manifold Kit
  • Material/Design: High-Si ductile iron, thick-wall, pulse-divided, slip-joint
  • Includes: EGR/turbo/exhaust gaskets, grade 10.9 bolts & spacers, pyrometer port
  • Warranty: 36 months / 75,000 miles
  • Install time: ~8 h 41 m
  • SEMA Cert: SC-BDD01-0155
  • Note: Not for sale on licensed California vehicles
  • Replaces Chrysler # 68205983AA

Pickup vs. Cab & Chassis: Which One Do You Need?

Spec Pickup (2500/3500) Cab & Chassis (3500/4500/5500)
Chassis/Packaging Standard pickup frame & downpipe routing Optimized for C&C accessory & exhaust packaging
Material & Casting High-silicon ductile iron, thick-wall runners & flanges
Thermal Management Slip joint to relieve heat-growth stress; resists warp & cracking
Turbo Feed Pulse-divided for quicker spool & lower drive pressure
EGR Compatibility Fully EGR-compatible (no tuning changes required)
Included Hardware EGR/exhaust/turbo gaskets • Grade 10.9 bolts & spacers • Pyro port
Warranty 36 months / 75,000 miles (parts)

Real-World Gains You’ll Feel

  • Faster turbo lighting pulling onto grades or into headwinds.
  • Lower EGTs at a given speed & load, especially with campers/trailers.
  • Fewer leaks & broken studs after heat cycles—clamp load stays put.
  • Cleaner turbine drive for steadier boost and better exhaust brake feel.

Install Tips for a Once-and-Done Seal

  • Work cold. Soak studs with penetrant overnight; crack fasteners in sequence.
  • Chase threads & clean faces. Gasket surfaces and bolt holes must be clean and flat.
  • Dry gaskets, correct sequence. Start center-out in a cross pattern; use the supplied spacers.
  • Heat-cycle re-check. After the first full cool-down, verify torque to keep the seal set.
  • Add an EGT probe. Use the pre-drilled port to watch temps on long climbs.

Planning bigger airflow or towing heavy? Pair the manifold with BD’s Screamer VGT and keep the transmission cool with the 68RFE Thermostat Bypass for steadier lockup under load.

Warranty, Certification & Notes

  • Warranty: Parts coverage for 36 months / 75,000 miles.
  • Certification: SEMA Certification No. SC-BDD01-0155.
  • Sales note: Not for sale on licensed California vehicles—verify local regulations.
Choose your kit: Pickup 2500/3500 Manifold Kit • Cab & Chassis 3500/4500/5500 Manifold Kit

All specifications and notes are based on BD Diesel product documentation at time of writing. Always confirm year/trim fitment and follow the latest BD installation instructions.