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2004 Ram 2500 O2 Sensors & Exhaust Manifolds (FIXED) #2820004
09/12/20 02:29 PM
09/12/20 02:29 PM
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I have a nice 2004 Ram 2500 5.7 120K miles on it, which I only use for towing my 24ft trailer. Are these 5.7 Hemi's prone on having bad O2 sensors. The check engine light always on. I have changed Senors a few years ago. That only worked for a short time. Is something messing up my senors. I just changed the Spark plugs today. The right bank look great maybe a little lean, the left bank are running rich. The gas mileage is down a bit also.
About 7.5 miles to the gallon with the trailer and Cuda.
Anyone have troubles with this before
Bob

Last edited by VCODE; 09/30/20 09:50 AM.

Mom & Dad let me buy a brand new 70 Challenger R/T 440 Six-Pack Super Trac Pack when I was 17 (Robert what is a 440 Six-Pack)
Re: 2004 Ram 2500 O2 Sensors [Re: VCODE] #2820032
09/12/20 04:55 PM
09/12/20 04:55 PM
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What are the codes?

Re: 2004 Ram 2500 O2 Sensors [Re: NITROUSN] #2820034
09/12/20 05:07 PM
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Originally Posted by NITROUSN
What are the codes?

I know, I did not get codes yet.
Bob


Mom & Dad let me buy a brand new 70 Challenger R/T 440 Six-Pack Super Trac Pack when I was 17 (Robert what is a 440 Six-Pack)
Re: 2004 Ram 2500 O2 Sensors [Re: VCODE] #2820039
09/12/20 05:26 PM
09/12/20 05:26 PM
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Yep, Need the codes there Bob .

Or else anything is a guess

BUT, best I remember they're not known for repetitive O2 sensors failures
Did you use OEM sensors or aftermkts

Re: 2004 Ram 2500 O2 Sensors [Re: gtx6970] #2820145
09/13/20 07:07 AM
09/13/20 07:07 AM
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Originally Posted by gtx6970
Yep, Need the codes there Bob .

Or else anything is a guess

BUT, best I remember they're not known for repetitive O2 sensors failures
Did you use OEM sensors or aftermkts


Bill, actually it was done at the Dealer. So they must have been Mopar one's
I was thinking there is also a small exhaust leak on the right bank.
I do not use the trunk much.
I will get codes next week
Thanks Bob


Mom & Dad let me buy a brand new 70 Challenger R/T 440 Six-Pack Super Trac Pack when I was 17 (Robert what is a 440 Six-Pack)
Re: 2004 Ram 2500 O2 Sensors [Re: VCODE] #2820759
09/14/20 06:55 PM
09/14/20 06:55 PM
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Originally Posted by VCODE
Originally Posted by gtx6970
Yep, Need the codes there Bob .

Or else anything is a guess

BUT, best I remember they're not known for repetitive O2 sensors failures
Did you use OEM sensors or aftermkts


Bill, actually it was done at the Dealer. So they must have been Mopar one's
I was thinking there is also a small exhaust leak on the right bank.
I do not use the trunk much.
I will get codes next week
Thanks Bob


Not uncommon for dealers to use aftermkt parts.
So dont count on they did use OE


Ps. Exhaust leak will cause o2 sensor issues

Re: 2004 Ram 2500 O2 Sensors [Re: gtx6970] #2820975
09/15/20 08:43 AM
09/15/20 08:43 AM
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Originally Posted by gtx6970
Originally Posted by VCODE
Originally Posted by gtx6970
Yep, Need the codes there Bob .

Or else anything is a guess

BUT, best I remember they're not known for repetitive O2 sensors failures
Did you use OEM sensors or aftermkts


Bill, actually it was done at the Dealer. So they must have been Mopar one's
I was thinking there is also a small exhaust leak on the right bank.
I do not use the trunk much.
I will get codes next week
Thanks Bob


Not uncommon for dealers to use aftermkt parts.
So dont count on they did use OE


Ps. Exhaust leak will cause o2 sensor issues


Bill, I have found out that most if not all 5.7 hemi engines have this problem with the exhaust manifolds warping and breaking the bolts. Well after looking that is exactly what's wrong with mine.Rich spark plugs on the left side and lean spark pugs on the right side where it is leaking. I am going to get new Mopar gaskets, dorman bolt kit and have the original manifolds resurfaced to correct that problem. I think this will fix all of my issues.
Thanks Bob


Mom & Dad let me buy a brand new 70 Challenger R/T 440 Six-Pack Super Trac Pack when I was 17 (Robert what is a 440 Six-Pack)
Re: 2004 Ram 2500 O2 Sensors [Re: VCODE] #2821697
09/16/20 07:12 PM
09/16/20 07:12 PM
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Broken exhaust manifold bolts on late model hemis is VERY common.
Seems to be mainly the ones towards the rear.
Probably has a lot to do with the steel manifold against the aluminum head

maybe look at using the cupped washers like on old hemi or LA small blocks ?

Re: 2004 Ram 2500 O2 Sensors [Re: gtx6970] #2821754
09/16/20 10:40 PM
09/16/20 10:40 PM
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I probably do 2-3 5.7 broken exhaust studs a week.... if your lucky it snaps near the top instead of even with the head. I’ve been using a step drill bit to hog out the holes on the sealing side of the manifold on the end ports. I also put a generous bead of copper rtv around the end ports on the gasket. Knock on wood I haven’t had a comeback doing it this way.

Re: 2004 Ram 2500 O2 Sensors [Re: J_BODY] #2821924
09/17/20 01:50 PM
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Originally Posted by J_BODY
I probably do 2-3 5.7 broken exhaust studs a week.... if your lucky it snaps near the top instead of even with the head. I’ve been using a step drill bit to hog out the holes on the sealing side of the manifold on the end ports. I also put a generous bead of copper rtv around the end ports on the gasket. Knock on wood I haven’t had a comeback doing it this way.


I just purchased the Mopar gaskets,bolts and nuts. $250.00 with my discount.
I am going to have the old manifolds resurfaced if out of spec before putting them back on. I got the Mopar gaskets which are a few layers thick. So you enlarge the inside end holes of the manifold to release some pressure on it.
It looks like my right rear broke at the top of manifold but not sure yet.
Thank Bob


Mom & Dad let me buy a brand new 70 Challenger R/T 440 Six-Pack Super Trac Pack when I was 17 (Robert what is a 440 Six-Pack)
Re: 2004 Ram 2500 O2 Sensors [Re: VCODE] #2823669
09/22/20 02:38 PM
09/22/20 02:38 PM
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Originally Posted by VCODE
Originally Posted by J_BODY
I probably do 2-3 5.7 broken exhaust studs a week.... if your lucky it snaps near the top instead of even with the head. I’ve been using a step drill bit to hog out the holes on the sealing side of the manifold on the end ports. I also put a generous bead of copper rtv around the end ports on the gasket. Knock on wood I haven’t had a comeback doing it this way.


I just purchased the Mopar gaskets,bolts and nuts. $250.00 with my discount.
I am going to have the old manifolds resurfaced if out of spec before putting them back on. I got the Mopar gaskets which are a few layers thick. So you enlarge the inside end holes of the manifold to release some pressure on it.
It looks like my right rear broke at the top of manifold but not sure yet.
Thank Bob


Thanks Guys and J Body.
I finally got the manifolds off. Ended up with 5 broken studs. Got one out with welding the nut onto it flush with the head. Leaving the others for another day
Bob


Mom & Dad let me buy a brand new 70 Challenger R/T 440 Six-Pack Super Trac Pack when I was 17 (Robert what is a 440 Six-Pack)
Re: 2004 Ram 2500 O2 Sensors [Re: VCODE] #2823675
09/22/20 02:49 PM
09/22/20 02:49 PM
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Most of the time you can just back them out easily. The aren't stuck in the head normally. I managed to remove mine with my fingers or a pair of pointed vise grips.

Re: 2004 Ram 2500 O2 Sensors [Re: stumpy] #2823693
09/22/20 03:18 PM
09/22/20 03:18 PM
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Originally Posted by stumpy
Most of the time you can just back them out easily. The aren't stuck in the head normally. I managed to remove mine with my fingers or a pair of pointed vise grips.


Not mine, 2004 Ram, they are rusty and tight. Even the ones that came out without breaking I needed to pull as hard as I could on the ratchet.
Thanks Bob


Mom & Dad let me buy a brand new 70 Challenger R/T 440 Six-Pack Super Trac Pack when I was 17 (Robert what is a 440 Six-Pack)
Re: 2004 Ram 2500 O2 Sensors [Re: VCODE] #2823719
09/22/20 04:25 PM
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That's weird. The broken off bolts in the three hemis I've done (2011, 2012, 2014) have all been finger tight. The unbroken ones are hard to get loose but I think that is because they are rusted to the manifold rather than the head. Just my experience your's may be different.

Re: 2004 Ram 2500 O2 Sensors [Re: stumpy] #2823743
09/22/20 05:06 PM
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We had a guy who was REALLY good with a mig welder. he would lay a nut over top of what ever was left of the stud . and 90% of them time he had them out in a few minutes

Re: 2004 Ram 2500 O2 Sensors [Re: gtx6970] #2823759
09/22/20 05:32 PM
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Originally Posted by gtx6970
We had a guy who was REALLY good with a mig welder. he would lay a nut over top of what ever was left of the stud . and 90% of them time he had them out in a few minutes


Better yet start with a flat washer. Being thinner it is easier to get penetration to the broken stud. Then weld a nut with a larger hole to the washer. The heat will transfer and help loosen the stud. Aluminum heads usually will allow easier sud removal. We always removed the inner fenders for access.

Re: 2004 Ram 2500 O2 Sensors & Exhaust Manifolds [Re: NITROUSN] #2823783
09/22/20 06:21 PM
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Originally Posted by NITROUSN
Originally Posted by gtx6970
We had a guy who was REALLY good with a mig welder. he would lay a nut over top of what ever was left of the stud . and 90% of them time he had them out in a few minutes


Better yet start with a flat washer. Being thinner it is easier to get penetration to the broken stud. Then weld a nut with a larger hole to the washer. The heat will transfer and help loosen the stud. Aluminum heads usually will allow easier stud removal. We always removed the inner fenders for access.


Yes that's my next step with the washer first.
Thanks Bob

Last edited by VCODE; 09/23/20 06:47 AM.

Mom & Dad let me buy a brand new 70 Challenger R/T 440 Six-Pack Super Trac Pack when I was 17 (Robert what is a 440 Six-Pack)
Re: 2004 Ram 2500 O2 Sensors & Exhaust Manifolds [Re: VCODE] #2824113
09/23/20 01:05 PM
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Originally Posted by VCODE
Originally Posted by NITROUSN
Originally Posted by gtx6970
We had a guy who was REALLY good with a mig welder. he would lay a nut over top of what ever was left of the stud . and 90% of them time he had them out in a few minutes


Better yet start with a flat washer. Being thinner it is easier to get penetration to the broken stud. Then weld a nut with a larger hole to the washer. The heat will transfer and help loosen the stud. Aluminum heads usually will allow easier stud removal. We always removed the inner fenders for access.


Yes that's my next step with the washer first.
Thanks Bob


Well I finally got all the broken bolts out .Let me tell you, two studs where so tight I needed to use my 1/2 breaker bar. I mig welded the washer on first then I welded a large nut onto that. This worked the best for me.
Now off to have them machined flat.
Thanks Bob


Mom & Dad let me buy a brand new 70 Challenger R/T 440 Six-Pack Super Trac Pack when I was 17 (Robert what is a 440 Six-Pack)
Re: 2004 Ram 2500 O2 Sensors & Exhaust Manifolds [Re: VCODE] #2824181
09/23/20 02:59 PM
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Originally Posted by VCODE
Originally Posted by VCODE
Originally Posted by NITROUSN
Originally Posted by gtx6970
We had a guy who was REALLY good with a mig welder. he would lay a nut over top of what ever was left of the stud . and 90% of them time he had them out in a few minutes


Better yet start with a flat washer. Being thinner it is easier to get penetration to the broken stud. Then weld a nut with a larger hole to the washer. The heat will transfer and help loosen the stud. Aluminum heads usually will allow easier stud removal. We always removed the inner fenders for access.


Yes that's my next step with the washer first.
Thanks Bob


Well I finally got all the broken bolts out .Let me tell you, two studs where so tight I needed to use my 1/2 breaker bar. I mig welded the washer on first then I welded a large nut onto that. This worked the best for me.
Now off to have them machined flat.
Thanks Bob


Glad it worked out. Years ago we went to the washer trick first and it worked almost without fail unless someone had previously buggerd the threads. We used to do the nut first and almost always it was 5 to 10 tries. The washer first about 50 percent or better come out on the first try.

Re: 2004 Ram 2500 O2 Sensors & Exhaust Manifolds [Re: NITROUSN] #2824187
09/23/20 03:10 PM
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Yes the washer first worked out way better than just the bolt welded on. With the washer you can get a better weld on the broken stud. But it takes time I still had a few welds break. No meat and a tight bolt
Bob


Mom & Dad let me buy a brand new 70 Challenger R/T 440 Six-Pack Super Trac Pack when I was 17 (Robert what is a 440 Six-Pack)
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