Remove and replace the exhaust resonator on a 1966 Chevrolet Corvette 327ci V8 to restore proper exhaust tone and flow.

Warnings

Tools required

Parts

• Exhaust resonator × 1 — Use OEM specification or equivalent aftermarket
• Exhaust clamp kit (2-bolt type) × 2 — 2.5" diameter
• Exhaust hanger insulators × 2 — Replace if deteriorated

Preparation

1. Ensure engine and exhaust system are completely cool to the touch
2. Park vehicle on level ground and engage parking brake
3. Place wheel chocks behind rear wheels
4. Raise rear of vehicle using floor jack at rear differential or frame rail
5. Support vehicle securely on jack stands placed at reinforced frame points
6. Spray all exhaust clamp bolts and hanger mounting points with penetrating oil and allow 15-20 minutes soak time

Procedure

1. 1

   Locate the resonator assembly
   Position yourself under the rear center of the vehicle. The resonator is a cylindrical canister located between the dual muffler outlets and the tailpipe inlets, suspended by rubber hanger insulators. On the 1966 Corvette, it sits approximately 18 inches forward of the rear bumper at the center of the undercarriage.
2. 2

   Inspect hanger connections
   Identify the two rubber hanger insulators that support the resonator. These connect from the resonator body to frame-mounted brackets. Check their condition and note if they require replacement due to cracking, tearing, or excessive deterioration.
3. 3

   Remove forward exhaust clamp
   Locate the 2-bolt exhaust clamp connecting the muffler outlet pipes to the resonator inlet. Using a 9/16" socket and box-end wrench, remove the two clamp bolts. If bolts are seized, apply additional penetrating oil and use a wire brush to clean threads. Work bolts back and forth to break corrosion before attempting full removal.
4. 4

   Remove rear exhaust clamp
   Locate the 2-bolt exhaust clamp connecting the resonator outlet to the tailpipe assembly. Using a 9/16" socket and box-end wrench, remove the two clamp bolts. Set clamps and hardware aside for inspection.
5. 5

   Support the resonator
   With one hand supporting the resonator weight, use your other hand or a helper to prepare for disconnecting the hangers. The assembly weighs approximately 8-12 pounds.
6. 6

   Disconnect front hanger
   Using a pry bar or by hand, compress and twist the front rubber hanger insulator to release the resonator mounting tab from the frame bracket. Work the rubber grommet off the metal hook by pushing the resonator slightly forward and upward.
7. 7

   Disconnect rear hanger and remove resonator
   Compress and twist the rear rubber hanger insulator to release the resonator mounting tab from the frame bracket. With both hangers disconnected, slide the resonator rearward to clear the muffler outlet pipes, then lower and remove it from under the vehicle. The pipes may require slight twisting or rotation to separate due to carbon buildup.
8. 8

   Clean pipe connections
   Using a wire brush, clean the outer diameter of the muffler outlet pipes and the inner diameter of the tailpipe inlet pipes. Remove all carbon deposits, rust, and old gasket material to ensure proper seating of the new resonator and clamps.
9. 9

   Inspect and replace hangers if needed
   Examine the rubber hanger insulators removed with the old resonator. If cracked, torn, or hardened, install new hanger insulators onto the new resonator mounting tabs before installation. Fresh hangers ensure proper support and reduce vibration transmission.
10. 10

    Position new resonator
    Lift the new resonator into position under the vehicle. Align the inlet end with the muffler outlet pipes, sliding the resonator forward approximately 2-3 inches onto the muffler pipes. Ensure the resonator orientation matches the original, with inlet and outlet properly positioned.
11. 11

    Connect front hanger
    Compress the front rubber hanger insulator and hook the resonator mounting tab onto the frame bracket. You may need to use a pry bar to stretch the rubber slightly. Ensure the tab is fully seated in the frame hook.
12. 12

    Align rear connection and install rear hanger
    Slide the tailpipe assembly forward approximately 2-3 inches onto the resonator outlet pipe. Compress the rear rubber hanger insulator and hook the resonator mounting tab onto the frame bracket. Adjust the entire assembly for even gaps at both clamp locations.
13. 13

    Install and tighten front clamp
    Position a new or cleaned exhaust clamp over the muffler-to-resonator joint. Ensure the clamp is centered over the joint with equal pipe overlap on both sides. Hand-thread both bolts, then tighten in an alternating pattern using a 9/16" socket and wrench. Tighten firmly until clamp deforms slightly and provides secure connection without crushing pipes.
14. 14

    Install and tighten rear clamp
    Position a new or cleaned exhaust clamp over the resonator-to-tailpipe joint. Ensure the clamp is centered over the joint with equal pipe overlap on both sides. Hand-thread both bolts, then tighten in an alternating pattern using a 9/16" socket and wrench. Tighten firmly until clamp deforms slightly and provides secure connection.
15. 15

    Final alignment check
    Inspect the entire exhaust system from mufflers to tailpipes. Verify that no component contacts the frame, body, or rear suspension/differential components. Check for even hanger tension and proper pipe alignment. Adjust clamp positions if needed before final verification.

Reassembly

1. Verify all clamp bolts are tight and evenly torqued
2. Ensure all hanger insulators are properly seated on frame brackets
3. Confirm adequate clearance between exhaust components and body/frame (minimum 1 inch)
4. Remove jack stands and lower vehicle to ground

Verification

• Start engine and listen for exhaust leaks at clamp joints (hissing or ticking sounds indicate loose or misaligned clamps)
• With engine at idle, visually inspect all connections for smoke or exhaust gas escaping
• Rev engine to 2000-2500 RPM and recheck for leaks
• Take vehicle for test drive and listen for rattles, vibrations, or exhaust contact with body components
• Perform final visual inspection of clamps and hangers after test drive to ensure nothing has shifted

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