aFe Power Bladerunner Manifolds Exhaust

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

Part #: 46-40011

Overview

The aFe Power Bladerunner Exhaust Manifold is a precision-engineered upgrade designed specifically for the 2003 to 2007 Dodge Ram 2500 and Ram 3500 trucks equipped with the 5.9L Cummins engine. This high-performance manifold replaces the factory unit to address common issues such as cracking and warping, while significantly improving exhaust flow and engine responsiveness. Built for Cummins enthusiasts who demand durability and enhanced performance, the Bladerunner manifold delivers reliable power gains without sacrificing emissions compliance.

By upgrading to the aFe Bladerunner manifold, drivers will benefit from quicker turbo spool times, improved throttle response, and overall enhanced engine efficiency. It is an ideal solution for those looking to maintain daily drivability, support heavy towing, or pursue performance improvements with a dependable, long-lasting component.

Key Features

Engineered with advanced materials and design, the aFe Bladerunner manifold offers superior performance and durability. Key features include:

• Constructed from premium cast 304 stainless steel for exceptional strength and corrosion resistance
• Reinforcing rib along the flange and ultra-thick wall flange at the port to prevent cracking and warping
• Thick wall design measuring 0.25" compared to the stock 0.15" for enhanced structural integrity
• 23% greater exhaust flow than the factory manifold, improving turbo efficiency and throttle response
• Merged runner design to optimize exhaust gas flow and reduce turbulence
• Matched port surfaces for precise fitment and superior sealing against the cylinder head
• Two pre-installed EGT (Exhaust Gas Temperature) probe ports for accurate temperature monitoring
• 50-state legal with CARB Executive Order Number D-550-9, ensuring compliance with emissions regulations

Construction & Design

The Bladerunner manifold is expertly crafted from cast 304 stainless steel, a material renowned for its heat resistance and durability under extreme operating conditions. Its thick 0.25-inch wall thickness and reinforced flange design significantly reduce the risk of cracks and warping that commonly plague factory manifolds.

The manifold’s merged runner layout is engineered to streamline exhaust gas flow, minimizing backpressure and enhancing turbocharger efficiency. Matched port surfaces ensure a precise seal against the cylinder head, preventing leaks and maintaining optimal exhaust flow for improved engine performance and longevity.

Performance & Sound

Upgrading to the aFe Bladerunner manifold results in noticeably faster turbo spool-up times and sharper throttle response. The increased exhaust flow capacity reduces backpressure, allowing the turbocharger to operate more efficiently and deliver power more quickly. While primarily focused on performance gains, this manifold also refines the exhaust pulse for a cleaner, more efficient flow, subtly enhancing the engine’s sound character without excessive noise.

Installation & Fitment

The Bladerunner manifold is designed as a direct bolt-on replacement for the factory manifold on 2003–2007 Dodge Ram 2500 and Ram 3500 trucks equipped with the 5.9L Cummins engine. Installation requires no major modifications, making it suitable for professional installers and experienced DIY enthusiasts alike. The inclusion of two EGT probe ports allows for easy integration with existing exhaust temperature monitoring systems.

What's Included

• aFe Power Bladerunner Cast 304 Stainless Steel Exhaust Manifold
• Two pre-installed EGT probe ports
• Installation hardware (if applicable)
• Instructions with proper installation and torque specifications

Ideal For

This exhaust manifold is perfect for Dodge Ram 2500 and 3500 owners with the 5.9L Cummins engine who want to eliminate factory manifold cracking issues while enhancing performance and throttle response. It suits daily drivers, towing enthusiasts, and performance-minded individuals seeking a reliable, emissions-compliant upgrade that improves turbo efficiency and engine durability.

Emissions Note

The aFe Power Bladerunner Exhaust Manifold is 50-state legal for 2003–2007 Dodge Ram 2500 and 3500 models, certified under CARB Executive Order Number D-550-9. It meets all applicable emissions standards, ensuring legal use on public roads throughout the United States.

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.