Tail Pipe

Removal and replacement of the tail pipe section of the exhaust system on a 2009 Aston Martin DB9 6.0L V12, including disconnection from the rear muffler or resonator and removal of exhaust hangers.

Warnings

Tools required

Parts

• Tail pipe assembly × 1 — Use OEM Aston Martin specification or approved aftermarket
• Exhaust flange gasket × 1 — Use OEM specification
• Rubber exhaust hangers (if damaged) × 2 — Inspect and replace as needed

Preparation

1. Ensure engine and exhaust system are completely cold to the touch
2. Raise vehicle on lift or support securely on jack stands at all four corners, ensuring adequate working clearance underneath
3. Apply penetrating oil to all visible exhaust flange bolts and hanger mounting points, allow to soak for 15-30 minutes
4. Inspect tail pipe routing and hanger locations from rear of vehicle forward to muffler/resonator connection point
5. Have fire extinguisher accessible in case of unexpected heat-related issues with residual deposits

Procedure

1. 1

   Access the exhaust system
   Position yourself under the rear of the vehicle with adequate lighting. Locate the tail pipe section which extends from the rear muffler/resonator assembly to the rear bumper exit points. On the DB9, the V12 exhaust typically routes to twin rear mufflers with dual tailpipe tips per side exiting through the rear valance; verify the exact tip configuration against the specific vehicle before ordering parts. Identify the flange connection point where the tail pipe connects to the muffler or mid-pipe section. Note: On the DB9, the V12 exhaust routes to tail pipes exiting through the rear valance (verify whether dual or quad tip configuration on this specific vehicle before ordering parts).
2. 2

   Locate and inspect exhaust hangers
   Identify the rubber exhaust hangers supporting the tail pipe. The number of rubber hangers supporting the tail pipe must be confirmed by inspection on this specific vehicle; count and mark all hangers before removal. Inspect hanger condition for cracking or deterioration. Note hanger locations for reassembly reference. Note: The tail pipe section is supported by rubber hangers mounted to the chassis; verify the exact number of hangers for this vehicle before beginning, as the twin-muffler layout may use more than two. Note: The tail pipe is supported by rubber hangers mounted to the chassis; confirm the exact hanger count and locations for the 2009 DB9 before disassembly.
3. 3

   Remove heat shield fasteners (if equipped)
   If a heat shield is present over or near the tail pipe section, remove the Torx or E-Torx fasteners securing it. These are typically T30 or E12 fasteners. Set heat shield aside for reinstallation. Clean fastener threads with a wire brush if corrosion is present.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
4. 4

   Disconnect tail pipe flange from muffler
   Locate the flange connection between the tail pipe and the upstream muffler or resonator section. Remove the flange bolts securing the connection. Verify the actual connection type before proceeding — the DB9 may use a band/V-clamp or a bolted flange. If bolted, expect a small number of bolts per flange; confirm exact count, size, and head type (hex or Torx) against Aston Martin service documentation for this specific vehicle. If bolts are severely corroded, apply additional penetrating oil and allow to soak. Avoid open-flame heat near the rear valance, body panels, and fuel/brake lines on this aluminum-bodied vehicle; if heat is required, use controlled induction heating and keep a fire extinguisher accessible. Support the tail pipe with one hand or have an assistant support it as you remove the final fasteners. Note: The exact bolt count, size, and head type for this flange must be verified against Aston Martin service documentation for this specific vehicle before proceeding; do not assume socket size. Note: The flange fastener count, head type, and size for this connection must be verified against Aston Martin service documentation for the 2009 DB9 before proceeding; do not assume generic 13mm/15mm or Torx fasteners.
   Torque spec

   Exhaust Flange Bolt25 Nm (18 lb-ft)
5. 5

   Remove old flange gasket
   Once the flange is separated, remove and discard the old exhaust gasket from the flange surfaces. Use a wire brush or scraper to clean both mating surfaces on the tail pipe flange and the muffler flange, removing all carbon deposits and old gasket material. Ensure surfaces are flat and free of debris for proper sealing.
6. 6

   Release exhaust hangers
   Working from rear to front, disconnect the tail pipe from the rubber exhaust hangers. Using an exhaust hanger removal tool or pry bar, compress or pry the rubber hanger to release the metal hook on the tail pipe. The rubber hangers remain attached to the chassis. If hangers are damaged or excessively worn, mark them for replacement.
7. 7

   Remove tail pipe assembly
   With all fasteners and hangers disconnected, carefully lower and remove the tail pipe assembly from the vehicle. Maneuver the pipe to clear the rear valance, chassis components, and any brackets. Be mindful of sharp edges on cut exhaust pipe ends. Inspect the removed tail pipe for damage, excessive corrosion, or internal restriction.
8. 8

   Inspect and replace rubber hangers
   With the tail pipe removed, inspect all rubber exhaust hangers for cracks, tears, or excessive wear. Replace any damaged hangers by removing the fastener securing the hanger bracket to the chassis (typically a 13mm or E-Torx bolt). Install new rubber hangers if needed, ensuring they are properly oriented and secured to the chassis.
9. 9

   Prepare new tail pipe for installation
   Unpack the new tail pipe assembly and verify it matches the removed component in length, diameter, flange position, and hanger hook locations. Install a new exhaust flange gasket onto the flange of the new tail pipe or onto the mating flange on the muffler/resonator. Apply a thin coat of anti-seize or high-temp exhaust-rated lubricant to the threads of the flange bolts only if the specified torque is a lubricated value; otherwise install dry per the manufacturer specification. Do not apply anti-seize to fasteners that are torqued to a dry specification.
10. 10

    Position and support new tail pipe
    Lift the new tail pipe into position, aligning the flange with the muffler/resonator outlet flange and positioning the hanger hooks near their corresponding rubber hangers. You may need an assistant or a support stand to hold the tail pipe in position while you work. Ensure the tail pipe exits are properly aligned with the rear valance cutouts.
11. 11

    Connect tail pipe to exhaust hangers
    Engage each hanger hook on the tail pipe with its corresponding rubber hanger on the chassis. Use an exhaust hanger tool or pry bar to stretch the rubber hanger over the metal hook. Work from front to rear. Ensure hangers are fully seated and the tail pipe is supported properly before proceeding.
12. 12

    Install flange bolts
    With the flange gasket in place and flanges aligned, insert the flange bolts and hand-tighten. Install all bolts finger-tight first, ensuring the gasket remains properly positioned and the flanges are flush. Using a torque wrench and appropriate socket, tighten the flange bolts (or clamp fasteners) in a cross-pattern to the manufacturer-specified torque. Confirm the exact torque value against Aston Martin service documentation before final tightening. Confirm that anti-seize was applied only if the torque value is a lubricated specification; otherwise the threads should be clean and dry per manufacturer specification. Note: Using a torque wrench and appropriate socket, tighten the flange bolts in a cross-pattern to the manufacturer-specified torque (verify the exact value in Aston Martin DB9 service documentation before final tightening). Note: Using a torque wrench and appropriate socket, tighten the flange bolts in a cross-pattern to the Aston Martin specified torque for this connection (verify exact value in OEM service documentation before final tightening).
    Torque spec

    Exhaust Flange Bolt25 Nm (18 lb-ft)
13. 13

    Reinstall heat shield (if equipped)
    If a heat shield was removed in Step 3, position it back over the tail pipe and align mounting holes. Install the Torx or E-Torx fasteners and torque to the manufacturer-specified value (verify in Aston Martin DB9 service documentation; typical heat shield fasteners are light-torque only). Ensure the heat shield does not contact the tail pipe directly and has proper clearance. Note: Install the Torx or E-Torx fasteners and torque to the manufacturer-specified value; confirm the exact torque against Aston Martin DB9 service documentation before final tightening. Note: Install the heat shield fasteners and torque to the Aston Martin specified value (verify exact torque and fastener type in OEM service documentation).
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)
14. 14

    Verify tail pipe alignment and clearance
    Visually inspect the entire tail pipe installation. Verify that the tail pipe exits are centered in the rear valance cutouts and positioned symmetrically (if dual exhaust). Check for adequate clearance between the tail pipe and all chassis components, body panels, suspension components, and the rear fascia. Adjust hanger positions slightly if needed to optimize alignment. The tail pipe should hang evenly without stress on any connection point.

Reassembly

1. Reassembly is accomplished by following the removal steps in reverse order
2. Always use a new exhaust flange gasket; never reuse the old gasket
3. Apply anti-seize compound to all exhaust fastener threads to facilitate future service
4. Ensure all rubber hangers are fully engaged and not twisted or stressed
5. Verify tail pipe tip alignment is centered in rear valance cutouts before final torque application

Verification

• Lower vehicle to the ground and start the engine
• Listen for exhaust leaks at the flange connection; a hissing or ticking sound indicates a leak requiring re-torquing or gasket replacement
• With engine running, walk to the rear of the vehicle and verify exhaust is exiting cleanly from both tail pipe tips without unusual noise
• Check for excessive exhaust system vibration or rattling against chassis or body components
• Visually inspect from underneath for proper hanger engagement and tail pipe alignment while engine is running
• Allow engine to reach operating temperature and re-inspect flange connection for leaks under heat expansion
• Take a short test drive and verify no exhaust drone, rattles, or contact with chassis components under acceleration and deceleration

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