Ram 5.7L HEMI Exhaust Manifolds (2009–2022): The “Tick”, Broken Bolts & The Real Fix

If your 5.7L HEMI sounds like it has a sharp tick on cold start—then quiets down as it warms up—there’s a strong chance you’re dealing with a manifold leak caused by warping, blown gaskets, or the classic culprit: broken manifold bolts/studs. This guide shows you how to confirm it (and avoid misdiagnosing valvetrain noise), why it keeps happening, and how a properly engineered replacement manifold kit fixes the problem long-term.

Quick Summary: Most “HEMI tick” complaints fall into two buckets: (1) exhaust manifold leak (often cold-start loud, warm quieter) and (2) valvetrain/lifter-related noises (often consistent and tied to oil pressure/engine condition). This post focuses on the manifold side: how to spot it, why bolts break, and how to install a manifold kit that’s built for heat cycling—thicker casting, better hardware strategy, and improved sealing.

Jump to: Symptoms • Why It Fails • How to Confirm • Fix Options • Why BD Manifolds • Install Tips • FAQs

1) Symptoms: What a HEMI Exhaust Manifold Leak Sounds Like

A leaking HEMI exhaust manifold usually announces itself with a sharp tapping/ticking that’s strongest right after startup. As the manifold warms up, it expands and the leak can partially “seal,” making the noise fade. That’s the classic pattern that separates many manifold leaks from deeper internal engine noises.

Common manifold-leak clues
  • Cold-start tick that gets quieter after a few minutes.
  • Exhaust smell in the engine bay or near the wheel well.
  • Black soot marks near the manifold flange or gasket area (visual smoking gun).
  • Tick increases under light throttle near idle and low RPM (load changes leak dynamics).
  • Heat shield rattle (sometimes secondary—caused by loosened hardware/warped alignment).

Important: The internet labels everything as “HEMI tick.” But a lifter/valvetrain tick often behaves differently: it may be more constant hot/cold, may change with oil pressure, and won’t typically leave soot at the manifold flange. Treat this as a diagnostic process, not a guess.

2) Why Ram 5.7L Manifolds Warp & Bolts Break

Exhaust manifolds live in the harshest environment on the truck: repeated heat cycles, high thermal gradients, and constant expansion/contraction. Over time, those cycles can create a tug-of-war between the manifold casting, the cylinder head, and the fasteners holding everything together.

Heat cycling + stress = fastener failure

When the manifold expands and contracts thousands of times, the system can lose clamp load. Once clamp load drops, gases start leaking, temperatures spike locally, and that accelerates warping and fastener fatigue. That’s why the “fix” is not only the casting—it’s also the hardware strategy and the mating surfaces.

Warped flanges create uneven sealing pressure

A flange that isn’t perfectly flat won’t distribute clamp load evenly. The gasket takes the beating first, then the leak starts, then everything gets worse. A better manifold design increases durability by resisting warping and maintaining a reliable sealing interface.

3) How to Confirm the Leak (Before You Buy Parts)

You don’t need guesswork. Use a simple, repeatable approach to confirm an exhaust manifold leak on a 5.7L HEMI.

Fast Diagnostic Playbook
  1. Cold start listen test: Stand near the wheel well / fender area with the hood open. Manifold leaks often “tick” from the side of the engine.
  2. Visual check: Look for black soot tracking near the manifold-to-head flange or gasket line.
  3. Feel test (carefully): With proper safety and avoiding moving/hot parts, you can sometimes feel pulsing near the leak area.
  4. Smoke test: A smoke machine into the exhaust (shop method) makes leaks obvious.
  5. Rule out heat shield rattle: Tap heat shields lightly (engine off) and check for loose hardware that can mimic ticking.

4) Fix Options: What Works (and What Comes Back)

There are three common paths owners take when fixing HEMI exhaust manifold leaks. Only one of them reliably stops repeat failures:

  • Replace a gasket only: Often temporary. If the flange is warped or clamp load is compromised, a fresh gasket becomes a short-term band-aid.
  • Replace with an OEM-style manifold: Works initially, but many trucks repeat the same cycle under similar heat/stress conditions.
  • Upgrade to a heavy-duty manifold + better hardware approach: This targets the root cause: warping resistance, stress distribution, and clamp load retention.

5) Why BD’s 5.7L HEMI Exhaust Manifold Kit Is Built to Last

BD designed their HEMI manifold kit around the real-world failure points: heat cycling, warping, and fastener stress. This is an OEM replacement style solution that upgrades the materials and design approach for durability.

BD Exhaust Manifold Kit — Ram 5.7L HEMI (2009–2022)
• High-silicon ductile iron construction
• Uniform, increased wall thickness to reduce stress risers and cracking risk
• Longer bolts + added spacers (15mm longer) to reduce stress on fasteners
• Machined bolt mating surfaces for secure joints
• Heat shield mounting bosses with independent mounting location strategy
• Gaskets, bolts, spacers included
• SEMA certification + CARB EO noted on product listing

View the BD 5.7L HEMI Exhaust Manifold Kit
Browse all related options: BD HEMI Manifold Collection

Flow gains (bonus benefit)

Reliability is the goal, but flow improvements can help overall efficiency too. BD publishes a measured average flow improvement on the kit listing, which is a nice side benefit when replacing restrictive or compromised factory manifolds.

6) Install Tips: How to Avoid Broken Bolt Nightmares

Exhaust manifold jobs go smoothly when you plan for the real enemy: seized or broken fasteners. Here are practical best practices that reduce “stuck bolt” drama and help the new manifolds seal correctly.

Installer tips that matter
  • Soak fasteners early: Penetrating oil over a day or two (heat cycles help) improves removal success.
  • Use the right extraction strategy: If a bolt snaps flush, plan for proper extraction (left-hand bits, heat, welding a nut, or machine shop).
  • Clean mating surfaces: A perfect seal requires clean head surfaces—remove old gasket material carefully.
  • Follow torque procedures: Tighten evenly and in sequence to prevent distorting the manifold during installation.
  • Re-check after heat cycles: Some installers verify hardware after initial heat cycling (follow service guidance).
  • Inspect heat shields: Bent or loose shields can create noises that sound like a leak even after the fix.

FAQs: Ram 5.7L HEMI Exhaust Manifolds

Is the “HEMI tick” always an exhaust manifold leak?
No. The term gets used broadly. A manifold leak commonly ticks on cold start and quiets warm, and may show soot near the flange. Valvetrain noise often behaves differently. Diagnose before buying parts.

How do I know if I broke a bolt?
Missing bolt heads, uneven flange gap, or a persistent leak near one cylinder are common clues. Sometimes the bolt breaks in the head and you won’t know until removal.

Will a manifold upgrade change drivability?
The primary change is restoring a sealed exhaust path and eliminating noise/leaks. Many owners notice smoother operation under load simply because the system is sealed and heat is managed correctly.

Does this affect emissions legality?
Always verify compliance for your jurisdiction. BD lists emissions documentation on the product page and notes compliance details on the listing.

Bottom line: If your Ram 5.7L tick is a manifold leak, the long-term fix is a manifold solution engineered for heat cycling: thicker, more durable castings + smarter hardware strategy + proper installation. That’s how you stop repeat failures.

Always verify fitment by year/model and follow the installation manual and torque procedures. Keep emissions equipment intact and compliant.