Guide to 2009-2024 Dodge Durango Exhaust Manifold Hardware Replacement
That ticking noise from your Durango's engine is a common problem you can fix.
- A ticking noise when your Durango is cold is the number one sign of a broken exhaust manifold bolt.
- This is an extremely common problem, especially on 5.7L Hemi engines.
- Upgrading to an aftermarket kit with studs and nuts can be a more durable, long-term solution than replacing with OEM-style bolts.
- The cost of this repair can increase dramatically if bolts are broken flush with the cylinder head and require extraction.
Is Your Durango Ticking? It's Probably a Broken Manifold Bolt
If you own a 2009-2024 Dodge Durango, especially one with a 5.7L Hemi V8, you might hear a distinct ticking or tapping noise when the engine is cold. This sound often quiets down as the engine warms up. This is a classic symptom of a broken exhaust manifold bolt. The extreme heat from the exhaust causes the metal bolts to expand and contract, and over thousands of cycles, they can snap. This is a very common issue on these trucks. When a bolt breaks, it creates a small gap that lets exhaust gases escape, causing the ticking noise.
🎬 Watch: A mechanic explains how to diagnose the Hemi tickKnown Issues and TSBs
Chrysler has issued Technical Service Bulletins (TSBs) for ticking noises related to the exhaust manifolds on 2019-2022 Dodge Durangos with the 5.7L Hemi engine. TSB 09-019-23 and 09-011-22 address a cold engine ticking noise and involve replacing the exhaust manifolds with an updated kit. This indicates the manufacturer is aware of the problem. While no specific recalls exist for the hardware itself, the issue is widely documented by owners and mechanics.
Choosing the Right Aftermarket Hardware
When replacing your exhaust manifold hardware, you have a choice between OEM-style bolts and aftermarket kits that often feature an upgraded design.
- OEM-Style Bolts: These are similar to what the factory installed. While they will work, they may be prone to the same failure down the road.
- Aftermarket Stud & Nut Kits: Many aftermarket kits, like some from Motormite (Dorman), replace the original bolts with studs and nuts. This is often considered a more durable, long-term repair. The stud is threaded into the cylinder head, and a nut is used to clamp the manifold down. This design can better handle the heat cycles and stress that cause the original bolts to break.
Brand Options: Motormite vs. Skyward
When shopping for your kit, you'll see brands at different price points. Here’s what to know:
- Motormite (Dorman): This is a well-known and widely available aftermarket brand. They offer direct replacement hardware as well as upgraded "OE FIX" kits, which often include stainless steel studs and nuts for better corrosion resistance and durability. They are a trusted option for this specific repair.
- Skyward: This is a more budget-oriented brand. While they provide a cost-effective solution, information on the long-term durability of their specific exhaust hardware is limited. For a critical and labor-intensive job like this, investing in a higher-quality kit with proven materials is often recommended to avoid doing the job twice.
Pro Tip: Always replace the exhaust manifold gasket when you replace the hardware. It's a small additional cost that ensures a proper seal and prevents you from having to take everything apart again. Also, inspect the manifold itself for cracks or warping, as this is another common failure point.
| Brand Tier | Price Range |
|---|---|
| Standard Replacement (Skyward, etc.) | $22.18 - $35.00 |
| Upgraded/Premium (Motormite/Dorman OE FIX) | $35.00 - $63.77 |
Frequently Asked Questions (FAQ)
Can I just replace the one broken bolt?
While you technically can, it's not recommended. The other bolts have been subjected to the same stress and are likely weakened. It is best practice to replace all the hardware on that manifold at the same time to ensure even clamping force and prevent future failures.
Why do aftermarket kits use studs instead of bolts?
Studs can provide a more consistent clamping force and are less likely to snap from the rotational stress of being tightened. The stud stays stationary in the aluminum cylinder head, and the nut does the work, reducing the chance of damaging the threads in the head. This design is generally considered more robust for high-heat applications.
What happens if a bolt is broken off flush with the engine head?
This is the biggest risk with this repair. If a bolt breaks off, it must be extracted. This often requires specialized tools to drill out the bolt and can sometimes involve welding a nut onto the broken stud to back it out. This can significantly increase the difficulty and labor cost of the repair. Attempting to extract a bolt without the right tools or experience can damage the cylinder head, leading to a much more expensive repair.
🎬 See how to extract a bolt broken flush with the headDo I need to replace the exhaust manifold too?
You should always inspect the manifold when you replace the hardware. The same heat cycles that break the bolts can cause the cast iron manifold to warp or crack. Lay a straight edge across the manifold's mating surface to check for warping. If it's not perfectly flat, or if you see any cracks, it must be replaced to get a proper seal.
🎬 Watch this step-by-step guide to replacing the Durango exhaust manifoldHelpful Videos
Technical Specifications
OEM Part Numbers: 53013892AA 6508218AA 6508219AA
Kit typically contains a mix of bolts, studs, and nuts to mount one exhaust manifold. Material is often steel, with premium aftermarket options using stainless steel for improved corrosion resistance.
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The information in this article is provided for general reference and educational purposes only. Vehicle specifications, procedures, and part compatibility can vary by production date, trim level, and region. Always consult your vehicle's factory service manual and verify part numbers before purchasing or performing repairs. Safety-critical components such as airbags, seat belts, and braking systems should be installed by a qualified professional.
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