Possibly a blown head gasket? I know that will cause a miss out of the exhaust, and probably some blow-by.
Hmmmmm... ... Jim...
Could this truck you knew about been anyone we BOTH might know and possibly how he did it,LOL.

:-laf :-laf . BTW... Do you think that there would be ANY chance of this certain owner. since he is so experienced at the repair job doing it again. Oh wait... I forgot you and Josh did all the work and he supervised...
For those of you the defend DC, wait until you have something that should be under warranty denied when there is no reason for the warranty to be denied, THEN see what you have to say about that... I personally enjoy every single time that someone gives it to DC... since they are WAY to eager to void or not warranty repairs, serves them right.
steved...
It would be my opinion that those here are NOT defending D-C for their actions,but,I am also certain that if you were the friendly service manager who had to deal with customers like you,your attitude would be no different. One thing that many here on the various diesel boards maybe do not know or fail to remember is that when D-C purchases these great powerplants from Cummins they are also bought with no warranties from Cummins. D-C is the one who writes and backs the warranties on all of their Cummins powered Rams,not Cummins,and with the meare cost at times for parts,I am certain they have their reasons for what they do. The infamous "53" block should have showed you what I mean by that. Its well known they crack and Cummins was not doing ANY warranties on them,Dodge was,IF they failed within warranty limits.
I guess if your were in charge this would be the scenario... .
-Mr. Jabloney walks into the dealership and is very distressed about a failure of his new Cummins powered Ram. It blew the fuel rail apart due to excessive pressure and caught fire causing damage. He steps up to the desk of the friendly service writer,you steved, at the towns Dodge dealership and the ensuing conversation goes like this... .
-steved... Why hello Mr. Jabloney and how are you today?.
-Mr. Jabloney... NOT GOOD!. . This sackin frackin rackin Dodge blew the fuel rail apart and it caught fire on Saturday nite. Its here now,towed in and I DEMAND to know what your going to do to fix it.
-steved... Didn't I see you at the fairground on Saturday nite sled pulling?. Man,it was a good thing those firemen got to you quickly and extinguished the flames,or it could have been worse.
-Mr. Jabloney... Yeah it was,now what is Dodge going to do to FIX my truck?.
-steved... Well Sir,My very talented certified mechanic looked it over this morning and seen the damage and we have good news for you. Even though its easy to see you had many aftermarket accessories added and evidence of a fueling module being there,D-C will fix it ALL for only the cost of your deductable. Heck,while its down for warranty work see my secretary and she will set you up with a loaner vechicle. Depending on the parts availability and how soon they can be delivered we should have it fixed in no time flat.
-Mr. Jabloney... Well I am relieved,I thought you'd try that old "void the warranty" deal because of my modifications. We both know they don't hurt or cause any problems,RIGHT?.
-steved... No not at all,here we make sure we treat everyone with the utmost respect and never dispute their claims at all. Its always better for D-C to pay to fix whatever happens,even when it breaks doing what you enjoy to do like you did.
-Mr. Jabloney... Thanks a million steved,you will always get my business.
-steved... No problem,glad to help a owner out in his time of need. I'll call you as soon as its finished.
Mr. Jabloney smiles wide as he walks away knowing that his own selfishness just cost D-C alot of money out of their pockets. What does he care for anyway,at least it wasn't out of his pocket and never thinking that D-C could end up like another major manufacturer is lately,closing factories everywhere due to money issues.
Kinda evens sounds tacky and foolish doesn't it?.
So with that all thats left to say to you steved is this,look through both windows sometime and see if maybe you can vision what its like in their shoes. Yes,they,D-C,do make some stupid mistakes and are not perfect but anymore what brand name is?. I hope the grass is much greener with your next truck and let me know if you need help finding a home for that unwanted Ram as there are lots of owners who would LOVE to have it.
If they void your warranty, for whatever reason, you should get a check in the mail for the balance of unused warranty along with the void notice.
Hoot Ol Friend. .
You are correct if the warranty is the extended warranty paid by the owner. Hope all is well with the family and life is good. Drop me a note or call sometime... ... ... Andy