Muffler

Complete procedure for removing and replacing the exhaust muffler assembly on a 2009 Aston Martin DB9 6.0L V12, including disconnection from intermediate pipes and mounting hangers.

Warnings

Tools required

Parts

• Muffler assembly × 1 — Use OEM specification or aftermarket equivalent for DB9 V12
• Exhaust clamp kit (if not included with muffler) × 2 — 55mm V-band or sleeve clamp depending on system
• Rubber exhaust hangers × 4 — Replace if cracked or deteriorated

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure exhaust system is completely cool to the touch
3. Raise vehicle on lift or securely support on jack stands at manufacturer-specified jacking points
4. Spray all visible exhaust clamp bolts and hanger mounting points with penetrating oil and allow to soak
5. Inspect the entire exhaust system from below to identify routing, hanger locations, and connection points

Procedure

1. 1

   Locate muffler assembly and mounting points
   From beneath the vehicle, identify the muffler assembly located at the rear of the exhaust system. The DB9 features a dual rear silencer (muffler) configuration with the main muffler bodies positioned toward the rear of the vehicle near the rear axle, feeding the twin tailpipe exits at the rear valance (verify exact tailpipe count and configuration on this specific vehicle). Note the locations of the rubber exhaust hangers (count and positions to be verified on this specific vehicle) and the clamp connections to the intermediate pipes forward of the mufflers and to the tailpipe sections rearward. Note: The DB9 features a dual muffler configuration with the rear silencer bodies positioned toward the rear of the vehicle. Verify the exact location of the muffler bodies relative to the rear axle for this specific vehicle before proceeding. Note: The DB9 features a dual muffler configuration with the main muffler bodies positioned at the rear of the vehicle, aft of the rear axle, feeding the tailpipes.
2. 2

   Disconnect forward exhaust clamps
   Locate the connections joining the muffler inlet pipes to the intermediate pipes (verify whether these are flanged bolted joints or clamped joints on your specific system). Using the correct size socket for the installed fasteners, loosen and remove the clamp or flange bolts at both left and right connections. If clamps are corroded, apply additional penetrating oil and allow to soak. Remove the clamps completely and set aside. Gently separate the joints to break the seal—do not force if the connection is stubborn; apply more penetrating oil and allow additional soak time. Note: Locate the clamp connections joining the muffler inlet pipes to the intermediate pipes. Determine the clamp type (sleeve, V-band, or flange with gasket) and the correct fastener size for this vehicle before proceeding, then loosen and remove the clamp fasteners at both left and right connections. Note: Locate the clamp connections joining the muffler inlet pipes to the intermediate pipes. Identify the clamp type (sleeve-type, V-band, or flanged joint) and the correct fastener size for this specific system before beginning, then loosen and remove the clamp/flange bolts at both left and right connections. Note: Clamp or flange hardware per OEM specification — verify connection type (flanged bolted joint with gasket vs. V-band vs. sleeve clamp) and size against factory documentation before ordering
3. 3

   Disconnect rear exhaust clamps
   Move to the rear connections where the muffler outlets connect to the tailpipe assemblies. Using the correct size socket for this vehicle's clamp fasteners, loosen and remove the clamp bolts at both left and right tailpipe connections. Remove the clamps completely. Gently wiggle and pull the tailpipe sections rearward to separate them from the muffler outlets, providing clearance for muffler removal. Note: Using the correct size socket for the installed fasteners, loosen and remove the clamp or flange bolts at both left and right tailpipe connections. Note: Using the correct socket for this system's clamp fasteners (verify against factory documentation), loosen and remove the clamp bolts at both left and right tailpipe connections.
4. 4

   Support muffler assembly
   Position a jack stand, transmission jack, or have an assistant support the weight of the muffler assembly from below. The assembly is heavy and will drop once the hangers are released. Ensure stable support is in place before proceeding to hanger removal.
5. 5

   Remove exhaust hangers
   Locate the rubber exhaust hanger mounting points supporting the muffler assembly (verify the exact count against factory documentation before beginning). Using an exhaust hanger removal tool or a pry bar, carefully pry the rubber hanger isolators off their mounting studs on the chassis. Work methodically from front to rear or side to side, releasing one hanger at a time while maintaining support under the muffler. The rubber hangers may be stiff; wiggling while applying steady pressure will ease removal. Inspect each rubber hanger for cracks or deterioration and replace if necessary. Note: Locate the rubber exhaust hanger mounting points supporting the muffler assembly (verify exact count and positions on this specific vehicle before proceeding).
6. 6

   Lower and remove muffler assembly
   With all hangers disconnected and both forward and rear connections separated, carefully lower the muffler assembly using the support jack or with your assistant. Guide the assembly downward and rearward, ensuring it clears the rear axle assembly, fuel tank, and chassis components. Remove the muffler assembly from under the vehicle and place it on a clean work surface.
7. 7

   Inspect connection points and prepare for installation
   With the muffler removed, inspect the intermediate pipe and tailpipe connection surfaces for damage, excessive corrosion, or distortion. Use a wire brush to clean the mating surfaces of both pipes. Check the condition of all rubber exhaust hangers—replace any that show cracking, tearing, or hardening. Verify that chassis-mounted hanger studs are secure and not damaged. If installing a new muffler, compare it to the old unit to confirm proper fitment, hanger positioning, and inlet/outlet diameters.
8. 8

   Position new muffler assembly
   With assistance or using a jack, lift the new muffler assembly into position beneath the vehicle. Guide it upward and forward, aligning the inlet pipes with the intermediate pipes and the outlet pipes with the tailpipes. Do not fully seat the connections yet—leave approximately 1-2 inches of clearance to allow for hanger installation.
9. 9

   Install exhaust hangers
   With the muffler assembly supported in approximate position, install the rubber exhaust hangers onto the chassis-mounted studs. Begin with the forward hangers, then proceed to the rear. Use the exhaust hanger tool or pry bar to stretch the rubber isolators over the studs. Ensure each hanger is fully seated on its stud. Once all hangers are installed, allow the muffler to hang naturally—this will align the system for final connection.
10. 10

    Connect and secure forward clamps
    Reconnect the muffler inlet pipes to the intermediate pipe connections per the joint type on your system (install new gaskets if flanged). Apply a thin coat of anti-seize compound to the fastener threads if desired. Position the clamps or flanges over the joints and install the bolts finger-tight. Once both left and right forward clamps are positioned, torque the clamp/flange bolts to the factory-specified value for this exhaust system using a torque wrench (verify torque spec against Aston Martin service documentation).
    Torque spec

    Muffler Clamps55 Nm (41 lb-ft)
11. 11

    Connect and secure rear clamps
    Push the tailpipe sections forward onto the muffler outlet pipes, ensuring full engagement and proper alignment. Position the exhaust clamps over the joints and install the clamp bolts finger-tight. Verify that the tailpipe tips are evenly positioned relative to the rear bumper openings and are not in contact with the bumper or body panels. Adjust as necessary, then torque the clamp bolts to specification.
    Torque spec

    Muffler Clamps55 Nm (41 lb-ft)
12. 12

    Final inspection and clearance check
    Visually inspect the entire exhaust system from below. Verify that all clamps are torqued, all hangers are properly seated, and no part of the exhaust system contacts the chassis, fuel tank, rear axle, or body panels. Gently shake the exhaust system side-to-side and front-to-back to confirm secure mounting and adequate clearance throughout the range of motion. Check that exhaust tips are centered in the bumper cutouts and positioned symmetrically.

Reassembly

1. Reassembly is covered in the installation steps above
2. Ensure all clamp bolts are torqued to specification before lowering the vehicle
3. Double-check that all rubber hangers are fully seated on their mounting studs

Verification

• Lower the vehicle to the ground and start the engine
• Listen for exhaust leaks at the clamp connections—a hissing or ticking sound indicates a leak that requires re-torquing or gasket/clamp replacement
• Allow the engine to reach operating temperature and verify no unusual exhaust odors enter the cabin
• Perform a test drive and listen for rattling, buzzing, or contact noises that would indicate the exhaust is touching chassis or body components
• After the test drive and cool-down, re-inspect all clamp connections and hanger mounts for proper positioning and security

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