aFe BladeRunner Exhaust Manifold

Dodge Ram 2500 / Ram 3500 03-07 5.9L Diesel

Part #: 46-40012

Overview

The aFe BladeRunner Exhaust Manifold is a premium high-performance replacement designed specifically for the 2003 to 2007 Dodge Ram 2500 and Ram 3500 trucks equipped with the 5.9L diesel engine. Engineered to address the common cracking and warping issues found in the factory exhaust manifolds, this BladeRunner manifold delivers enhanced durability and improved exhaust flow for a more responsive and reliable driving experience.

Whether your original manifold is showing signs of failure or you want to upgrade proactively, the BladeRunner manifold offers significant benefits including reduced exhaust gas temperatures and better throttle response. It is an ideal solution for diesel enthusiasts who demand longevity and performance from their heavy-duty trucks without compromising reliability.

Key Features

Designed with precision and built to last, the BladeRunner Exhaust Manifold incorporates advanced features that outperform the stock manifold and enhance your truck’s exhaust efficiency:

• Improves exhaust flow by up to 23% over the factory manifold for increased efficiency
• Thick wall construction (0.25" thickness versus stock 0.15") enhances strength and resists cracking
• Ported flanges ensure a precise fit and excellent sealing to prevent exhaust leaks
• Merged runner design reduces exhaust backpressure, promoting faster turbocharger spool-up
• Dual 1/8 inch NPT ports for exhaust gas temperature (EGT) probes on each bank allow accurate monitoring
• Reinforcing rib along the flange adds structural integrity to withstand heavy-duty use
• Includes six port gaskets and all necessary mounting hardware for a complete installation

Construction & Design

The BladeRunner manifold is expertly cast from premium 304 stainless steel, providing superior corrosion resistance and strength compared to the factory ductile iron manifold. Its thicker walls and reinforced flange rib significantly reduce the risk of cracking and warping, common failure points in stock manifolds subjected to heavy loads and high temperatures.

The manifold’s merged runner design optimizes exhaust flow dynamics, allowing exhaust gases to exit more efficiently and reducing backpressure. This engineering not only extends the manifold’s lifespan but also supports improved engine performance under demanding conditions such as towing or heavy hauling.

Performance & Sound

By increasing exhaust flow by as much as 23%, the BladeRunner manifold promotes quicker turbocharger spool-up, resulting in enhanced throttle response and overall engine performance. Lower exhaust gas temperatures help protect turbo components and improve reliability during extended high-load operation. While focused on durability and performance, the manifold maintains a clean and efficient exhaust pulse without significantly altering the factory sound profile.

Installation & Fitment

The BladeRunner Exhaust Manifold is a direct bolt-on replacement for the factory manifold on 2003–2007 Dodge Ram 2500 and Ram 3500 trucks with the 5.9L diesel engine. Installation requires no modifications and includes all necessary hardware along with detailed instructions to ensure a straightforward upgrade. Ported flanges guarantee a precise fit and excellent sealing, minimizing the risk of exhaust leaks and simplifying the installation process.

What's Included

• BladeRunner Exhaust Manifold (304 stainless steel)
• Six port gaskets
• Complete mounting hardware
• Detailed installation instructions

Ideal For

This exhaust manifold is perfect for Dodge Ram 2500 and 3500 owners who want to eliminate the common cracking issues of the stock manifold while gaining improved performance and reliability. It is especially suited for diesel enthusiasts who tow heavy loads, operate in demanding conditions, or simply want to upgrade their truck’s exhaust efficiency and throttle response without extensive modifications.

aFe POWER (Advanced FLOW Engineering) offers dyno-proven intake, filtration, and exhaust upgrades aimed at measurable performance gains. The brand’s lineup is geared toward enthusiasts looking for better airflow, improved sound, and durable materials—from cold air intakes to stainless exhaust systems for street and track applications.