aFe BladeRunner Exhaust Manifold

2007–2010 Dodge Ram 2500 / Ram 3500 5.9L Diesel

Part #: 46-40054

Overview

The aFe BladeRunner Exhaust Manifold is a premium direct replacement designed specifically for 2007 to 2010 Dodge Ram 2500 and Ram 3500 trucks equipped with the 5.9L diesel engine. Engineered to address the common cracking and durability issues found in the factory cast iron manifold, the BladeRunner offers a robust and high-performance upgrade. This manifold enhances exhaust flow, reduces exhaust gas temperatures, and improves overall engine efficiency, making it an excellent choice for diesel enthusiasts seeking reliability and better performance without compromising emissions compliance.

Whether your original manifold is showing signs of wear or you want to proactively upgrade, the BladeRunner manifold delivers long-lasting strength and improved turbocharger response to support daily driving, towing, and performance applications.

Key Features

Combining durability with performance enhancements, the aFe BladeRunner Exhaust Manifold includes features designed for optimal function and ease of installation:

• Outflows the factory manifold by up to 49%, significantly increasing exhaust efficiency
• Improves throttle response and overall engine performance
• Cast-in EGR flanges maintain compatibility with the factory EGR system for emissions compliance
• Thick wall construction (0.25" vs. stock 0.15") enhances strength and prevents warping or cracking
• Machined ports and merged runner design reduce exhaust backpressure and turbulence
• Dual 1/8 inch NPT exhaust gas temperature (EGT) probe ports for precise monitoring on each bank
• Includes six-port gaskets to ensure a complete, leak-free seal
• All necessary mounting hardware included for hassle-free installation

Construction & Design

The BladeRunner manifold is crafted from premium 304 stainless steel, a significant upgrade over the stock cast iron manifold. This high-grade material offers superior resistance to cracking and corrosion, ensuring extended service life under the extreme heat and pressure conditions typical of diesel exhaust systems. The manifold walls are notably thicker at 0.25 inches compared to the OEM’s 0.15 inches, providing increased rigidity and durability.

A reinforcing rib along the flange further strengthens the manifold, preventing warping and maintaining a perfect seal over time. The exhaust runners are carefully merged and precision-machined to optimize exhaust flow, reducing turbulence and backpressure to enhance turbocharger efficiency and engine responsiveness.

Performance & Sound

By increasing exhaust flow by as much as 49%, the BladeRunner manifold promotes faster turbo spool-up and lowers exhaust gas temperatures. This results in improved engine performance, enhanced throttle response, and potential gains in fuel efficiency. While primarily engineered for durability and flow improvements, the manifold also contributes to a cleaner, more efficient exhaust pulse, subtly refining the diesel exhaust note without introducing unwanted drone or harshness.

Installation & Fitment

The aFe BladeRunner Exhaust Manifold is designed as a direct bolt-on replacement for 2007–2010 Dodge Ram 2500 and Ram 3500 trucks with the 5.9L diesel engine. Installation is straightforward and requires no modifications to the vehicle’s existing exhaust or emissions systems. The manifold comes complete with all necessary mounting hardware and detailed instructions, ensuring a smooth and hassle-free upgrade process.

What's Included

• aFe BladeRunner Exhaust Manifold (Part #46-40054)
• All required mounting hardware
• Six-port gaskets for proper sealing
• Detailed installation instructions

Ideal For

This exhaust manifold is ideal for Dodge Ram 2500 and 3500 owners who want to eliminate the common cracking issues of the stock manifold while gaining improved exhaust flow and enhanced engine performance. It is well suited for diesel enthusiasts seeking a reliable, long-lasting upgrade that maintains factory emissions compliance and supports better turbocharger efficiency. Whether used for daily driving, heavy towing, or performance applications, the BladeRunner manifold offers a durable and effective solution to upgrade your truck’s exhaust system.

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.